DAS Sport Rollbar Install DIY Porsche 996

Before we started carrying the Agency Power Rollbar for Porsche 996/997, I used to have a DAS Sport Rollbar in my car. Here are some tips for installing it in a 996/997 Coupe. The instructions published on the DAS Sport Website are pretty straight forward and with practice, the rollbar can be installed in about 45 minutes by yourself, though it’s always easier with a helper.

To begin, make sure you have enough room to maneuver with both doors wide open. You’ll need at least six feet free to maneuver on the passenger side. You don’t have to remove both seats, but it certainly is easier if you do, especially with fixed back seats. At a minimum, remove the passenger seat completely and remove the seat-bolts from the driver’s seat and move it as far forward as possible. If you car has seat-mounted airbags, as long as you do not turn the key with the airbags disconnected, you don’t have to worry about resetting the airbag warning light so make sure you don’t have to move the car once you start to work on this project. You will also be removing the carpet covering the ECU and strut mounts behind the rear seats. Consider if you want to carpet it or modify your current carpeting before you begin. It’s very difficult to try to put carpet back there once the bar is installed. You should also decide if you want to remove the rear seats or just leave them folded. You save a little weight by removing them, but with them folded you actually have more practical storage space in the back as you can use the folded seat as a shelf and stow small items on the seat below relatively out-of-sight from outside of the car. Using heavy beach towels, cover the center console, door plates and seat backs. The bar is very cumbersome to move around and you do not want to scratch your interior.

Carpet

Start by preparing to remove the seat-belt mounting bolts in the rear foot-well. Take time to note or photograph the way the seat-belt fits, especially the half twist that is necessary to get it to line up correctly. Check that you have the correct foot plate for each side and install the eye-bolts but do not tighten them. You will need to finish installing and tightening the upper bolts of the rollbar before tightening the eye-bolts. My carpet was cut — it is not required for this to fit properly and not recommended unless you plan to remove your carpet soon and don’t want to have to remove the rollbar.

Rearshelfuncovered

Remove the six nuts from the rear strut mounts. Note the angle of the mounting brackets on the rear section and turn it upside down. Carefully feed it into the car and rest it in the rear foot-well. Have someone help you flip it on to the rear strut mounting bolts. You will have to work it into position around the seatback stops and trim. Get all six openings into position and loosely tighten only the rear nuts to ensure it does not fall forward. Loosely tighten the remaining four nuts as well.

Installed rollbar

Orient the main rollbar as it will fit inside the car. Working from the passenger side, tip it so the bar is to the back and the foot is toward the front of the car, and work it in from the passenger side and around/over the driver’s seat before standing it up in the rear foot-well. It is cumbersome to move so consider wrapping the ends in shop towels to help prevent damaging your interior. Work the connectors to the rear section first and feed the bolts from inside to outside and tighten loosely. Put the foot into the driver’s side base and fit the bolt through from inside to outside. You will find one side will line up perfectly and the other will require some encouragement — this is normal. Encourage the other side to fit with a small rubber hammer and/or a very long flat-nose screw driver and fit the second bolt. Tighten both lower bolts loosely. If everything is lined up, tighten from rear to front, starting with the rear strut mounts and torque to spec. The last bolts to tighten will be the eye-bolts. Use a screw driver and a vice-grip to turn them, but do not over tighten.

Padding

Consider using bar padding on the main hoop starting at door sill height. Check your view with the rearview mirror before you buy padding. You may want to get the mini padding type that won’t extend down so far into your field of view. You may have to remove the cover on the seat-belt height adjuster slider on the B pillar if you still use the stock belts.