Custom roof rack

[Brownfaux]

So I searched and I couldn't find any threads about fabricating a whole roof rack. I'm using tapatalk, so maybe things are getting left out?

Anyway, title says it, I'm looking at building my own roof rack. I started welding about 6 months ago, and I've turned the corner on being able to produce decent results. Granted, my angle grinder comes in handy, but I'm confident I can build this to be safe on the road.

I'm using a lincoln power mig 140, and I have a great big gas bottle of C25.

Basically, I wanted to run my Yakima fairing and two steelhead bike mounts, but couldn't see it as possible without a whole custom setup. I didn't want to use the rail grabber attachment because I thought it looked funny and stuck up too high, plus I'd need another fairing.

What I'm thinking of is having the two biggest pieces bent into a rectangular shape of the right dimensions, then welding them together and building a a basket out of small steel stock, and adding two Yakima size bars at the right spot.

I can get the steel pretty cheap, probably all for under $80.

Does anyone have thoughts on this or pictures of custom setups they have done?

 

[darkie3495]

I think you're on the right track. I think designing and building your own is the way to go to ensure you get exactly what you want while saving money.

I designed my own roof rack:

and had a fabricator build it:

Same fabricator built my friend Mike's (RIP) as well and sounds similar to what you want to build:

One thing to note is that the roof curves from left to right and front to back. to compensate for this, you either have to make the legs that attach to your roof +2" tall or put a slight curve in your lower bars.

 

[Nathana92]

I think you're on the right track. I think designing and building your own is the way to go to ensure you get exactly what you want while saving money.

I designed my own roof rack:

and had a fabricator build it:

Same fabricator built my friend Mike's (RIP) as well and sounds similar to what you want to build:

One thing to note is that the roof curves from left to right and front to back. to compensate for this, you either have to make the legs that attach to your roof +2" tall or put a slight curve in your lower bars.

That's probably the best looking roof rack I've seen on a 4th gen.

 

[darkie3495]

That's probably the best looking roof rack I've seen on a 4th gen.

Thanks...much appreciated :cheers:

 

[Brownfaux]

Right on. That's what I'm looking for. The bracket looks like what I was picturing too.

What did you use to make the blueprint?

 

[darkie3495]

Right on. That's what I'm looking for. The bracket looks like what I was picturing too.

What did you use to make the blueprint?

I used Google Sketchup. it can also export .dwg files.

 

[estobaughn]

would you consider sharing that file and/or blueprint?

 

[Brownfaux]

Right on. I was hoping you'd say that. I had heard about it but hadn't downloaded it yet, but I am getting now.

What did your rack cost you total?

And did you run into any problems in the design or the build?

 

[Brownfaux]

And your runner looks awesome by the way.

 

[Adventure Copan]

darkie that is a good looking rack sir!

-Daniel Kent

 

[jdkilroy]

... I designed my own roof rack ...

Very nice design work on the rack Kevin. Are the middle feet just resting in the gutter for support or did you secure them somehow ?

 

[Tresvn]

That looks great,what size and type tubing did you use?

 

[Brownfaux]

Got sketch up and messed with it a bit. I'm definitely going to have to read some tutorial stuff. Did you make the lines and then tell it to substitute the lines with material of a certain thickness?

 

[darkie3495]

would you consider sharing that file and/or blueprint?

I'll have to go through my backup drives to see if I still have it. If I find it i'll shoot it over to you.

Right on. I was hoping you'd say that. I had heard about it but hadn't downloaded it yet, but I am getting now.

What did your rack cost you total?

And did you run into any problems in the design or the build?

I really can't remember how much it ended up coming to. It was quoted at a specific price then I agreed to a partnership with Perkins Performance to sell these rack through his company that lowered the price significantly.

I didn't run into any issues during the design process other than over engineering the rack. One design had hydraulic pistons that could fold the lights down and rotate via a cabin mounted control box (i'm a nerd). During the build process, the only issue was the bottom bar curvature had to be increased slightly to ensure proper clearance when you add weight to the roof due to tube flex.

And your runner looks awesome by the way.

darkie that is a good looking rack sir!

-Daniel Kent

Thank you both!!

Very nice design work on the rack Kevin. Are the middle feet just resting in the gutter for support or did you secure them somehow ?

Thanks!! Yes it's resting on the rubber gutter. It's strictly used for weight support as the stock mount locations are very secure.

That looks great,what size and type tubing did you use?

I used 1" OD 4130 Chromoly tubing all the way around with a total weight of 88lbs.

Got sketch up and messed with it a bit. I'm definitely going to have to read some tutorial stuff. Did you make the lines and then tell it to substitute the lines with material of a certain thickness?

Yeah, drawing a line first and use that as a guide for the tubing. It ensures that the measurements stay consistent.

 

[Brownfaux]

So draw the line, then create a shape that reflects the material size and drop it to the line? This may be one of those questions that's hard to describe. If its covered in the tutorial just tell me to read. I'll be spending some time on it tonight.

I really like the whole design of yours, but I was shooting for simplicity like a con-ferr rack. Easy for me to build, and no computer planning needed. Although I should get familiar with the program.

 

[Brownfaux]

Weight is a consideration. Thanks for posting the weight of yours. I'm going to calculate the weight of mine before I build it to make sure it's not excessive. I can work with mild steel, but other stuff would require more research.

 

[darkie3495]

So draw the line, then create a shape that reflects the material size and drop it to the line? This may be one of those questions that's hard to describe. If its covered in the tutorial just tell me to read. I'll be spending some time on it tonight.

I wish I found this when I was teaching myself, but this explains the method I use now: Sketchup PVC Elbow Fitting Tutorial - YouTube

I really like the whole design of yours, but I was shooting for simplicity like a con-ferr rack. Easy for me to build, and no computer planning needed. Although I should get familiar with the program.

Yeah, my rack design wouldn't be considered "simple" by any means. It is definitely easier to build on the fly when you have access to your truck 24/7. The fabricator's shop is an hour away so I had to schedule time to test fit and make adjustments.

Weight is a consideration. Thanks for posting the weight of yours. I'm going to calculate the weight of mine before I build it to make sure it's not excessive. I can work with mild steel, but other stuff would require more research.

Weight was a big concern for me as well. It could have been lighter but the benefits of handling more weight was greater than weight savings.

 

[Brownfaux]

Thanks for all the feedback. Now that I think about it more, for what I want to do the toughest part would be designing the brackets.

I like the look of yours, and can think of how to make my own, but yours look better. I've also debated buying another brand of bracket and the making my own rack. If you find the file could you share your bracket specs? Or better, does the guy you used still sell the racks?

Anyway, if i can get that then I'll have the top and bottom frame bent to my specs and then weld it all together myself.

 

[darkie3495]

Thanks for all the feedback. Now that I think about it more, for what I want to do the toughest part would be designing the brackets.

I like the look of yours, and can think of how to make my own, but yours look better. I've also debated buying another brand of bracket and the making my own rack. If you find the file could you share your bracket specs? Or better, does the guy you used still sell the racks?

Anyway, if i can get that then I'll have the top and bottom frame bent to my specs and then weld it all together myself.

You're talking about the legs, right? you don't have to over think those. it's just a piece of steel bent using a hydraulic press/brake. I did it the harder way by determining angles and all that crap. Just build your basket/rack then position it exactly where you want it at the right height (you can just use stacks of paper to achieve the clearance you need) then fab the mounts that way.

 

[Brownfaux]

It looked like yours had an angle in the bend. Are yours just bent parallel to the edges, or are they angled to compensate for the curve in the roof?