I am installing a halo and a pair of a-pillar bars to a car that already has an eight point set-up in it now. Where the halo bar connects to the main hoop above and behind the driver and passengers head, I cannot weld the top 1/4 of the tube because there is no room to get my tig torch. Therefore I plan to put a 3"x4"x3/16 gusset on the side facing each door. My question is, is there any specs on gussets or will the above gusset be just fine? Isnt there a spec for round tube gussets also? I put the 3 hole jegs gussets on my car but was going to just make a set for these , and would I have to gusset each side of the tube if I cannot weld in completely around?

I'm not sure that will fly with tech inspector. Usally the first place they look? How fast is this car? If its not CM, use a gassless MIG, or evan a stick welder, just bend the rod to weld the top.

When Rick Shrek cert.my chassis he told me that a gusset was needed on those areas,there was no spec.and Mig.weld was OK.He's the guy in charge of Top fuel spec.I'd call your local NHRA tech.guy and get an definitive answer,he's in Fl.PM me and I'll give you his #.

Hard to see in my pics

Even with a gusset...the tube must be welded all the way around or it won't cert.

Or get a short collet and cap, worked for me.

I do have a short collet and cap on my tig and it might fit but im anticipating not being able to get the very top as it is almost touching the headliner, ill put a piece of sheetmetal to reflect the heat but there still isnt alot of room, the owner of the car said he thought that if I welded 3/4 around somebody told him that gusset would be necessary then. I could probably bend the tip of a stick electrode of 3/16 7018 and get the top welded, that may actually be the easiest, I dont owm a mig. Judging by the other welding and fabricating on this car it wouldnt certify regardless of what I do, owner wants me to grind down a couple of ropey mig welds and reweld over them and I know that is a no-no! I just want to make sure that my work I perform on this car is up to snuff as it always is, dont you just love it when somebody brings over a POS and wants you to "do a little welding job".

Nomally in that place you would drop the cage through
the floor and then weld the top.... but I have seen
them pass with the gusset and it wasnt welded 100%
around

I don't know how it applies to what you are doing to this roll cage, but I have the SFI spec for 25.5 and there is an allowance for tubes not welded all the way around. It is pretty specific on the gussett as well. You are allowed to use a tube 4" long as a diagonal between the members and they even spec the plate gussett in detail if I remember correctly.

Ultimately it is up to the chassis inspector that is certing the cage though.