Custom roof rack build.

Z

Zmanring

New member
This all started with an old Thule rook basket about 7 years ago, since then it has been through 5 owners and now back to me. Some of my criteria that I needed in a basket for my 4th gen.

- Want to be able to still get into garages in Atlanta (Removed the handles that where on top of the basket and custom brackets that slide into the stock roof rack. Dropped rack down about 2.5in lower than if I used the stock cross members)
- Want to carry all kinds of wood (Made sure nothing was sticking up higher than the top bar)
- Short enough to open sunroof and huge the roof line (Hacked the front off and built a custom one)
- Place to mount my hi-lift and CB (Used the old handle location, welded new 45degree angle square stock and welded Skee offroad's hi-light mount to it)
- And of course lights (total of 6 mounts)

So.. Here's the progress..

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New clear faring installed, can't wait for the lights to come in this week!
 
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Looks good!, I have a similar idea in my head to make a low profile, but sturdy roof rack. Gobi's product is awesome but I'm hesitent to drop another $1400
 
Got the lights in today, looks like I might have to mod the light mounts on the rack... again! lol. That's what custom is all about. Looks like I have a project for this weekend.
 
Good job with the build. I really like to see people making parts so congrats on that. Keep us updated.

Unless i missed it did you use the factory rack side bars to mount the basket? It seems like it would be more secure and lower if you did away with the factory side rails and made mounts to bolt in the factory locations. That way you could get it lower and not even have to drill and tap any new holes. I dont think id trust too much side to side strength on the factory bar.
 
blkexp98 said:
Good job with the build. I really like to see people making parts so congrats on that. Keep us updated.

Unless i missed it did you use the factory rack side bars to mount the basket? It seems like it would be more secure and lower if you did away with the factory side rails and made mounts to bolt in the factory locations. That way you could get it lower and not even have to drill and tap any new holes. I dont think id trust too much side to side strength on the factory bar.
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Hey thanks, I was going to build custom side bars but I ended up making mounts that slide into the stock ones. The strength itself is so much better! And I'm not sure how much lower I can go, I already have problems getting a rachet underneath. :)
 
This is a mock of what I think the driving lights will look like when im done. I hope to fit in 2 fog lights on each side too. This weekend I will be breaking out the grinder and welding up the mounts. Enjoy.

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Removed existing light mounts and welded on new ones, lower. Wired up all 6 lights, next step is to get the switches in the truck.
 
Man, I feel like im the only one updating this thread. Thanks to the 500+ people who checked it out.

I want to point out OTRATTW in there excellent customer service when buying switches. For reasons I don't know USPS has lost my package, the tracking says they left a note... but where? Later found out I forgot to include my apt number. Ok.. so my fault.. woops. I call USPS and they can't help me at all! I need a pink slip they left on someone's door. So I emailed OTRATTW about this issue, and without hesitation they dropped shipped me another switch. Thanks a lot guys and will continue to do business with you!

In other news, I messed up and used the wrong gauge for my Hella 550's, so this weekend.. you guessed it, I will be tearing apart most of the work I did this past weekend and do it right! By the way, does anyone have a suggestion on the wire gauge I should use? I have 2 driving lights and 2 fog, bothed powered in pairs. Any insite will be much appreciated.
 
Looks awesome! I love that the lights don't stick up and are nicely hidden. Look forward to your progress and some closeup final pics. Would love to see it at night all lit up. I would go about as heavy gauge as you can...i think anything bigger than 8 gauge would be overkill though. How are you routing the wires inside? Just curious. But, nice rack! ;)
 
Zmanring said:
By the way, does anyone have a suggestion on the wire gauge I should use? I have 2 driving lights and 2 fog, bothed powered in pairs. Any insite will be much appreciated.
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I think 14 should be ok but it depends on how you have them wired and the length of wire from the relay to the light. I have 4 100W lamps on my rack with two relays (one switch) and I used 14 ga. because that was the recommendation I found by googling. The 2 55W PIAAs I have up there on the back only have 16 ga. because that's what the wiring harness included. Did the 550s not include harnesses?

Wiring Size Guide
 
Thanks, it's been a long time coming, but I see the light.. Haha pun.

The wiring harness that came with it was around 16 gauge but I think that was for 1 light and I didn't use that wire because of the length I need to go. They are all 55w pulling 4.5amp each. I'm thinking about going with 2 12gauge wire for each pair. And maybe a 10gauge for grounding the rack and use the two relays it came with. You think that would be enough?

Closeup
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The main wires run through the tube, the small wires to the lights are visible. Its all connected by a trailer harness, which will be changed this weekend :(
 
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