Hi Sean - thanks! yes, this is turning into a fun build!
As for your question, the roll bar is made of K&S aluminum tubing and 1/16" dia evergreen solid rod + small diameter brass rod, and CA.
OK - so that sounds pretty technical - it's less so than you think. I've been working with this combo for a couple of years and after lots of good, less good, bad, really bad, and other results I've gotten to a point where I fee pretty good about it.
The process is first to have a really good conceptual understanding of what you are trying to build!!!! Like from a clear photo of what a real roll cage looks like, at least for the first few attempts. I don't try to exactly replicate the real deal, but try to be reasonably close.
If you haven't built one of these before, you'll be surprised at how complicated something apparently so simple can become!!
I start with the aluminum work. You'll need a few key measurements: critical being overall height and width!!.
Next, bend the metal (I use a combo of pliers and fingers) to fit around/under/over things, like the slope of a windshield, pillars, seats, parts of dashboards, etc - to mount/install the aluminum tubing to the build and keep it rigid/plumb, I use small diameter metal rod, drilled and glued into whatever the base material is, then slide the tubing over it and glue in place.
This all sounds too complicated!! it's a bit complicated, and you'll need to think three dimensionally a few times - but, heck we're model builders!!!
Once the metal roll bar is in place I add the evergreen for bracing - you'll also see some extra photo-etch sprue material glued on (across the top) - the CA + brass + aluminum really keeps the shape in place as I beat it up building it!
As this has been so much fun - I've started a another truck! - this is one of the Meng hilux pickups - not to worry - I'm changing it up and it won't rely on too much of the kit other than the basic body - and the basic frame -
here it is:
you can see a part of the big Ford behind it - I'm not showing all of it yet - as the weathering isn't done yet -
I liked that truck so much, decided a smaller partner would be cool too!