01-26-2021, 06:12 PM
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#1
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Member
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Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Member
Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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My $400 DIY Roof Rack
After liking the look of the Prinsu roof rack but not wanting to spend close to $1,000 on a roof rack I decided to set out on making my own. I found this video on youtube that got me started.
https://www.youtube.com/watch?v=ylPZkwRBA5o
After watching this and honestly copying a lot of his ideas I started with some sketches.
I then got some card stock and started mocking everything up to make sure it would all fit. Allowing the back hatch to open, see out the sunroof and flow with the body lines.
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2006 Limited 4WD Metallic Silver
Bilstein 5100s Front and Rear, OME 885 Front and Icon Overland Rear, 1/4" Spacers for driver side, LT295/70R17 Cooper STT Pros, 1" RB Body Lift, 1.25" Wheel Spacers, Stock FJ Rims, Custom Aluminum Roof Rack, Land Cruiser Snorkel, LED interior swap, Cobra 19 Ultra III CB, Vinyl wrapped in Avery Matte Garnet Metallic
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01-26-2021, 06:20 PM
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#2
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Member
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Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Member
Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Once I felt comfortable with all the dimensions I spent about $250 at TNUTZ for the aluminum extrusions/hardware.
Another $90 from Grainger for the side panels and I had some stuff to start with.
While I was waiting I got some 3" angle iron from work. Due to the slope of the roof I did have a friend bend the angle iron in slightly with their press (not pictured). Then I bought some spacers from Ace Hardware, took off the old rack, cleaned the areas, and patched int the vinyl wraps.
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2006 Limited 4WD Metallic Silver
Bilstein 5100s Front and Rear, OME 885 Front and Icon Overland Rear, 1/4" Spacers for driver side, LT295/70R17 Cooper STT Pros, 1" RB Body Lift, 1.25" Wheel Spacers, Stock FJ Rims, Custom Aluminum Roof Rack, Land Cruiser Snorkel, LED interior swap, Cobra 19 Ultra III CB, Vinyl wrapped in Avery Matte Garnet Metallic
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01-26-2021, 06:24 PM
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#3
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Member
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Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Member
Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Once I got the aluminum sides I started drawing everything out on them.
Just like the original video I designed the rack to be split into two separate halves for easy assembly/storage if needed.
__________________
2006 Limited 4WD Metallic Silver
Bilstein 5100s Front and Rear, OME 885 Front and Icon Overland Rear, 1/4" Spacers for driver side, LT295/70R17 Cooper STT Pros, 1" RB Body Lift, 1.25" Wheel Spacers, Stock FJ Rims, Custom Aluminum Roof Rack, Land Cruiser Snorkel, LED interior swap, Cobra 19 Ultra III CB, Vinyl wrapped in Avery Matte Garnet Metallic
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01-26-2021, 06:30 PM
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#4
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Member
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Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Member
Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Once everything was cut I started piecing everything together and verifying all my measurements were going to fit. Somewhere along the way I decided I wanted to integrate a light bar (an extra $50 for a cheap ebay light bar).
__________________
2006 Limited 4WD Metallic Silver
Bilstein 5100s Front and Rear, OME 885 Front and Icon Overland Rear, 1/4" Spacers for driver side, LT295/70R17 Cooper STT Pros, 1" RB Body Lift, 1.25" Wheel Spacers, Stock FJ Rims, Custom Aluminum Roof Rack, Land Cruiser Snorkel, LED interior swap, Cobra 19 Ultra III CB, Vinyl wrapped in Avery Matte Garnet Metallic
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01-26-2021, 06:37 PM
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#5
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Member
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Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Member
Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Then using a little more card stock I started to build the front wind fairing. Part of the reason for this new roof rack was for it to be more aerodynamic and have less wind noise so my goal was to get it as flush with the front as possible. This took a few tries to make it look good and push as much air over the top as possible.
__________________
2006 Limited 4WD Metallic Silver
Bilstein 5100s Front and Rear, OME 885 Front and Icon Overland Rear, 1/4" Spacers for driver side, LT295/70R17 Cooper STT Pros, 1" RB Body Lift, 1.25" Wheel Spacers, Stock FJ Rims, Custom Aluminum Roof Rack, Land Cruiser Snorkel, LED interior swap, Cobra 19 Ultra III CB, Vinyl wrapped in Avery Matte Garnet Metallic
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01-26-2021, 06:42 PM
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#6
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Member
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Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Member
Join Date: Mar 2015
Location: Albuquerque, NM
Age: 33
Posts: 69
Real Name: Kyle
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Lastly after a quick sanding, a few coats of self etching metal spray, a few coats of semi-gloss black, and some time to dry and assemble. I had a finished roof rack.
__________________
2006 Limited 4WD Metallic Silver
Bilstein 5100s Front and Rear, OME 885 Front and Icon Overland Rear, 1/4" Spacers for driver side, LT295/70R17 Cooper STT Pros, 1" RB Body Lift, 1.25" Wheel Spacers, Stock FJ Rims, Custom Aluminum Roof Rack, Land Cruiser Snorkel, LED interior swap, Cobra 19 Ultra III CB, Vinyl wrapped in Avery Matte Garnet Metallic
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01-26-2021, 06:47 PM
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#7
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Registered User
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Join Date: May 2003
Location: Birmingham, AL
Age: 53
Posts: 8,446
Real Name: Morris
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Registered User
Join Date: May 2003
Location: Birmingham, AL
Age: 53
Posts: 8,446
Real Name: Morris
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Good job!
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01-26-2021, 07:31 PM
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#8
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Member
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Join Date: Jun 2019
Location: Bay Area
Posts: 380
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Member
Join Date: Jun 2019
Location: Bay Area
Posts: 380
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Looks great! I saw this video few weeks back and been thinking about making one as well. Just need to find the time lol.
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04 V6 4x4. Eibach Pro Truck Shocks, OME 885, Icon 2" Springs. JBA UCA. 255/75/17 Kenda Klever AT/2. Spartan rear locker(removed). PCK. Hidden Winch
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01-27-2021, 10:14 AM
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#9
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Join Date: Dec 2010
Location: Inwood, WV
Posts: 205
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Member
Join Date: Dec 2010
Location: Inwood, WV
Posts: 205
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Very nice!
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02-18-2021, 07:59 PM
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#10
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Junior Member
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Join Date: Feb 2021
Location: Edmonton, AB
Posts: 2
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Junior Member
Join Date: Feb 2021
Location: Edmonton, AB
Posts: 2
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I love this! Did you use 1/4" aluminum? What cutting tool did you use to create the front side rails?
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02-19-2021, 01:00 AM
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#11
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Senior Member
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Join Date: May 2014
Location: Rio Rancho, New Mexico
Posts: 2,052
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Senior Member
Join Date: May 2014
Location: Rio Rancho, New Mexico
Posts: 2,052
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I’m in Rio, what’s it gonna take to have you help me replicate this?!
Sent from my iPhone using Tapatalk
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02-19-2021, 08:58 PM
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#12
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Member
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Join Date: Aug 2016
Location: San Diego, CA
Posts: 181
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Member
Join Date: Aug 2016
Location: San Diego, CA
Posts: 181
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Great job! How much did you have to bend the mounting feet? Seems the only part that might be a bit hard without access to a press. Any chance you have a picture of the finished feet?
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Black 2008 Sport V6 4WD | Toytec BOSS 3/2 | JBA UCA | BFG KO2 255/75/17 | Rocksteady Skids | White Knuckle Sliders | TJM Front Bumper | Superwinch
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02-21-2021, 02:52 AM
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#13
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Member
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Join Date: Sep 2016
Location: New Jersey
Posts: 34
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Member
Join Date: Sep 2016
Location: New Jersey
Posts: 34
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That looks really good! and it looks better than some of the aftermarket racks that I've seen too. How long did it take you to build?
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03-03-2021, 01:53 PM
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#14
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Junior Member
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Join Date: Dec 2017
Location: Colorado Springs, CO
Posts: 7
Real Name: Rick
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Junior Member
Join Date: Dec 2017
Location: Colorado Springs, CO
Posts: 7
Real Name: Rick
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Looks Great!
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03-04-2021, 10:36 AM
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#15
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Junior Member
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Join Date: Feb 2021
Location: charlotte
Posts: 13
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Junior Member
Join Date: Feb 2021
Location: charlotte
Posts: 13
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What hardware did you go with for the taps from T-nutz? Going to make something similar as well. Tap size? length of extrusion?
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