Custom Roof Rack Build
I‘ve been working on my custom roof rack quite a bit lately. It will be similar to the one I built for my 3rd gen several years ago. The main purpose for the rack is to have a place to mount lights front, rear, and sides. And also to be able to mount things (mainly kayaks) on top. First I designed it in CAD:
Side view:
Top view:
Front view:
Its a simple low profile tubing design with 5 aluminum T-slot pieces for mounting things.
It will use black anodized 3” x .75” T-slot pieces from 80/20:
It will have two 18” lights in the front. (I wanted to do a single 36” light, but Diode Dynamics doesn’t make one in that length, so went with two 18’s). Two 12” lights in the rear, and three 6” lights on each side. I ordered the lights last Black Friday:
After the design was finalized, I ordered some custom bent 1.75” tubing from 4xInnovations. Same tubing size and bend radii as my rock sliders, so should match nicely. Started welding the tubing pieces together:
Here is the tubing setting at the correct height (on wood blocks) on the 4runner.
I had to create some hooks and a pulley system to hoist it up to the garage rafters and then be able to gently lower it onto the truck’s roof by myself. Worked great!
Lastly, I was able to get the two front cross-bars welded in place:
Currently working on the mount pieces for the aluminum extrusions, and then all the light mounts.
More to come!