Aluminum Roof Rack?

[J053619]

I am currently looking into making an all aluminum roof rack. However all I see are steel racks. Is there any particular reason steel is preferred, or is it primarily due to it being cheaper? I know steel is stronger, but I would never really put anything heavy on top. And if i do, the weight is going to be evenly distributed (wood, sheet rock, camping equipment, etc.).

So far the cross sections(bars) are either going to be 1/4" thick or 5/16" thick.

The main reason I am choosing aluminum is because it is easily accessible to me at work. Any opinions or suggestions would be appreciated. Thanks.

 

[BlackWorksInc]

Probably cheaper, easier to work with, ect? I originally bought a bunch of aluminium tubing to make my own roof rack, got as far as notching the pieces before I ran into trouble finding a bender and then life fell on me and I think I still have the Aluminum around or I gave it away or something... I don't remember.

 

[J053619]

Fortunately bending shouldn't be a problem. Also, mainly using aluminum since we buy in bulk and probably is going to run around the same price as buying random steel which we don't use. If bending becomes a problem, i'll probably just weld it then.

Other than that do you think it's a bad idea to go with aluminum as opposed to steel?

 

[BlackWorksInc]

None really, it comes down to cost, equipment, and skill.

Welding steel, even poorly can be done easily where as aluminium welding is much trickier. If you got the equipment and the skills I don't see it being an issue, I'm sure you're already aware that you'll need a thicker walled tubing than you would use for steel due to aluminum being a softer material, I believe I was using roughly 1/8" thick tubing.

 

[J053619]

Good, hoping there weren't any other issues such as durability. But yea, all the aluminum i'll be using is solid. 3/4" diamete tubing along with a custom company extrusion. Ill try designing it this weekend and see if i can put it into the works soon with our next bulk order. If i get it done i'll post my finished product here! Thank for your help man!

 

[ebg18t]

ARB makes an aluminum version. Quite a bite more $$ but it is lighter.

 

[swapmeet]

I've been eyeballing racks lately. If you get yours ironed out in aluminum and wanted to make/ sell some i'm sure there would be some interest on the forum.
:becky:

 

[BlackWorksInc]

I've been eyeballing racks lately. If you get yours ironed out in aluminum and wanted to make/ sell some i'm sure there would be some interest on the forum.
:becky:

That's a good point... I don't know when I'll ever get around to trying my idea out as I still need roof curvature measurements and bolt spacing data from where the factory unit bolts on. I'd be interested in seeing your project [MENTION=77033]J053619[/MENTION] when you're done as I always like seeing mods and neat ideas, I personally like more low profile units myself.

If anything, PLEASE post the bolt-spacing measurements (width between bolts, distance between them, ect) and the curvature of the roof if you can manage it (that's a harder one to measure) as many of us who want to make our own racks would be VERY grateful.

 

[J053619]

That's a good point... I don't know when I'll ever get around to trying my idea out as I still need roof curvature measurements and bolt spacing data from where the factory unit bolts on. I'd be interested in seeing your project [MENTION=77033]J053619[/MENTION] when you're done as I always like seeing mods and neat ideas, I personally like more low profile units myself.

If anything, PLEASE post the bolt-spacing measurements (width between bolts, distance between them, ect) and the curvature of the roof if you can manage it (that's a harder one to measure) as many of us who want to make our own racks would be VERY grateful.

I'd hope to start throwing together some ideas within a week or two. I have to see if i can grab material or ill need to order extra for our production.

But in terms of the curvature, I think I may just use the stock rack to measure it. Any thoughts on that?

When I get home tonight Ill try to do a quick bs rendering to show you at least the extrusion i would be working with.

 

[J053619]

I've been eyeballing racks lately. If you get yours ironed out in aluminum and wanted to make/ sell some i'm sure there would be some interest on the forum.
:becky:

Haha I'm just hoping it looks good if i manage to put it together. If people are impressed by it that would be something else.

Just don't know if i should powder coat it flat/matte black or black wrinkle

 

[J053619]

Just a quick little update/rendering on this project:

Rough Draft of the rack

Extrusion Profile

That's just a mock up. I haven't taken dimensions yet due to lack of time. The tubing is 3/4" as i mentioned in an earlier post.
The cross bars used to weld the two rails are either going to be 1/4" or may be 5/16," i haven't decided yet.

I'll most likely have an adapter that slides on the 3/4" tubing to allow me to use most after market accessories which require 1" tubing.

The front of the rack is angled because i want to have a fairing with a machined logo to reduce wind noise.

Thanks for input [MENTION=66389]BlackWorksInc[/MENTION] & [MENTION=72341]NJshadow93[/MENTION]