Willievee;
If you can weld and have an oxy torch, you can make nice bends in steel. Get your roll bar material and get it all measured out. Make a wooden pattern of the inside of your curve. Weld a cap on one end of the tube and fill it with dry white sand(Home depot sandbox sand). Fill it really tight, tap it in until it is flush with open end. Weld the open end. Now you can heat the tube where you want it to bend red to orange hot and lay it in your pattern. You can bend it easily with your protected hands or 2X4 and the sand will keep the tube from colasping. Do this outside with a couple of your buddies, you will need help in handling a big hot tube of steel and it will burn and smoke the pattern immediately. Have a bucket of water and a hose ready because as soon as the tube has cooled down enough to retain its shape, you want to remove the hot metal from the pattern and let it cool slowly. Pour water on the pattern just as soon as you can without getting the steel wet. You should be able to get at least two bends out of the pattern. Make your "U" a little long and then trim after all of the bending is done. If you want you can use a piece of PVC the same size as the roll bar material, plug and fill with dry sand, heat with a heat gun, bend it around your pattern and check to see if your calculations were correct. If the PVC fits perfectly, you can take that to a fab shop and say " make this shape out of roll bar material".
Two things to worry about in addition to the oblivious, first make sure the sand is dry(if wet it can turn to steam and blow out the tube both steel and PVC), second drill a 1/8" hole in one end cap so it can't happen.
Mike
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