Update. Looking pretty good to me. So far my cost estimates put it around $300-350 depending on a few extras. According to Sherpa, the 3rd gens roof rails are flat... I'm still a bit unsure about that but I'm going to get a single crossbar (1" x 2" x 40.5") and a few brackets to test with. Sherpa's feet are the best in terms of ease of use and design, but at $22.50 a pop they are pretty expensive. So I am going to experiment with 2 hole L brackets with metal spacers to clear the side of the rails. More photos to follow...

Here is the most recent design.

no clue, but should be easy to test with a level or angle finder, just put it on the existing rails, or the roof if no rails, and see if it shows different side to side.

Not That hard to account for given the load limitations of the roof itself, you Really want the rack attachment points to fail before the roof. Means those brackets aren't going to be Overly stout (you won't be using a standoff of more 80/20), something like a bent steel bracket (which can be bent to the right angle easily enough).



Gut feeling is that they ARE angled.

Yeah I feel like they are...but maybe if I hope enough they will magically be flat... lol

I guess I will need to get some kind of angle measurement tool. Also need to figure out how to mount the rails as low as possible to keep the profile low. I was hoping to be able to mount them directly to the rails if I can... I don't plan on loading them with an outrageous amount of weight. Haha

Need to see if I can upload a drawing or something... Basically I'm thinking 5 or 6 cross bars that each mount to the roof rails then two long, double bars to mount to each respective side of the crossbars. This will give it a "lip" on the sides. Then on the front and rear I'll use the curved bars to hopefully cut down any potential noise.

Going to take some measurements tonight and see how wide and long of bars I'll need.

You could consider getting some of these handy Sherpa feet just to save yourself the pain of fighting the angled roof rails, and then make your own rack attaching to the feet.

Adjustable Track Mounting Feet

Oh
MY
Lord

YESSSS!!!

Holy shit that is amazing. But wait, is that $30 per bracket or per a set? I was thinking about doing 5 cross bars so that might be expensive...haha

Making your own rack that is Cheap, Strong and Easy? - Pick 2.

Yes, the roof curves. I thing it's about 3/8" total difference.

Here is a link to my build:
SoSueMe Gobi Roof Rack

You 100% don’t need to do 5 crossbars with roof attachments. I’d do 2x per side MAX 3x per side.. (you can still put 5x crossbars just don’t attach all of them) Way strong enough with just 2x the only thing is if your doing a full length rack your going to want feet that rest near the sun roof to support the front of your rack. I got something like this to support the front of my DIY rack. (Not exactly these but you get the idea)

Hyever Heavy Duty Leveling Screw Leg 4" Adjustable Feet Leveler Foot for Furniture Mechanical Equipment Pack of 2 - - Amazon.com

So far my estimate is around 200-300. Now it could probably be done for less than that but I'm choosing to make it a little nicer just because I want to.

Honestly these extruded aluminum bars are pretty cool, I was not aware of such until I learned about it just the other day.


You think so? I wasn't really intending the sidebars to actually carry load, but I guess they could. That's an interesting idea.

I did come up with a different support bracket idea, but I've got to do some math tomorrow to figure out if it's more or less expensive than the pre-made brackets.

I think I'll opt for 3 bars with attachments just for maximum strength. (Although again I'm probably going to never push this thing to its limits, but I always like to overbuild things for longevity) maybe one of each in, and one in the middle to make it balanced!

I also discovered that some of these companies sell finishing attachments, so like pieces that can fill the gaps in to make them smooth and stuff, end caps, but the coolest one are these rubber strips that fit into the slots! To add grip and stuff. Pretty awesome.


All right so I finished my basic design tonight, I'll try to figure out how to upload a screenshot to see what you guys think.

I mean I’m just going off of how the companies that make these racks do it. They use like 3/16 or 1/4” thick flat aluminum for the sides then the ends of the extruded aluminum are drilled/tapped and you throw a bolt threw the flat aluminum side pieces into the extruded aluminum. Were you basically planning on not having side plates?

5 crossbars is a lot. What are you carrying? I have a big rotopax, a high lift, flagpole, and often firewood on 3.

Umm... that's the only way Possible. The roof itself is a flexible sheet of thin steel. Takes maybe 5 pounds of force to deflect it. The crossbars (and/or platform) are only there to carry the load to the side rails/attachment points to transfer the load into a structural section.

Oh no, I'm definitely going to have side plates I just wasn't planning on them really carrying the load. Basically if all the cross bars attached to the roof, then the side rails would just kind of be there but wouldn't necessarily be structurally required.

I figured it would be easier to strap things down with side rails plus I just think it looks better.

I don't know cargo or luggage I guess. The crossbars are basically the bottom of my desire. So all the cargo will set directly on the crossbars. So the more crossbars there are the less giant gaps in between. Although I've also thought about using expanded aluminum or something to give more of a platform so small things can't fall through... But I haven't fully decided on that yet

Whoops, forgot to reply to this quote... Lol.

Yeah so that's why I was opting for 5 connected crossbars. To make sure the load is evenly distributed onto the factory rails.

This video might be of some help to you: Build Your Own (Better) Roof Rack - Improvements On The $300 DIY Roof Rack - YouTube

Hey that is pretty cool. Gonna check it out during lunch.

Ohh, do you guys know the best place to order the connectors from? I was looking at 80/20, which their price per bar is pretty cheap to me, but the connectors are nuts. I guess it's like PVC, the pipe is cheap as hell but the damn fittings kill ya.