Roll bar construction, part 2

This roll bar is costing me a lot of hours, but it is finally starting to look right.
I spent a couple more hours working at the straps radius, to get them right.

Then I marked the rivet locations, and began drilling the straps to the roll bar sections.

Fast forward a few hours…

Then I cut some wood blocks to 1⅜”. These will work as spacers between the sections, to ensure the roll bar becomes 1½” thick. I cut 3 more blocks than shown in this picture.

The forward sections clamped down.

…the centre lined up!

Then I removed every second cleco, and marked and drilled the forward section rivet locations.

I did the same thing to the outer strap rivets. After all holes were drilled, I took everything apart. Then I deburred the holes and adjusted the flanges of the forward sections, to reduce gap. After clecoing everything together and rechecking the dimensions, I began enlarging the holes to the final ⅛“.

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