How do you keep roll bars flat and square, and keep the corners at a precise 90º (or any other) angle? Use a 6-inch square.
Cold-bend plastic rod to fit into the inside angle of the square and tape it in place. Heat the plastic with a heat gun so the rod will take the exact shape of the inside angle. (If you're using aluminum or brass, you won't need to heat the material).
To get the bends on each side to be square with each other, use a second square and attach it to the same rule. If you don't adjust the width, this "double-square" can be used to build as many identical sections as needed. It can also be used to build the top hoop of the roll cage and any other pieces that need to be the same width.
Angled bars can be made the same way, using a carpenter's angle gauge that's adjustable and locks into place with a wing nut.
This tool is handy for making odd-angled bends on one or both ends of a piece of stock." – Ed Maslin
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