DIY "Gobi Style" Roof Rack Build

[jakerunner]

Added a Wind Deflector!

Cheers

 

[weiasian]

SO awesome!!! how did you weld the tube to tube joint? do you have a detail picture?

 

[Todapwr]

Wow the rack came out great!

 

[weiasian]

Awesome work!!! how was the tube welf together at the joint? Can I see a pic at that joint? and how long was the tube? 20 feet? one tube for each top and bottom piece?

 

[jakerunner]

Awesome work!!! how was the tube welf together at the joint? Can I see a pic at that joint? and how long was the tube? 20 feet? one tube for each top and bottom piece?

Sorry just getting to this. I used a pipe notching tool to round the end of each piece to be jointed. It certainly made the welding easier. Below is a picture of a couple of the joints. Please don't judge, as this was my first time wire welding in several years, and my welds are ugly, but they got the job done. I borrowed the welder, and so I didn't have the luxury of a lot of practice.

For the top and bottom tube frames, I ended up having to weld in a 3 foot section in the rear, as my 20 foot sections wouldn't quite cover the length needed.

 

[Eitek1]

Great project...

I was thinking that the pipe bending would be the most tedious and time consuming part. I looked online and you can find prebent 90 degree bends for about 12 dollars a piece. It's not as cool but it is an option for folks without a shop.

As far as the patent infringement thing, I don't think you are in any danger because you aren't selling anything. That doesn't stop them from trying something though and like you said, you're a college student who doesn't need the hassle.

It would be great if the community could crowd-source a design. I'm sure most communities have shops with CNC plasma cutting systems. My local guy charges about 15 cents per foot.

I believe that this could be done pretty easy and it could be an open source design. If a private company wanted to make them to sell, that would be fine too. For the hobbyists they could order from the BOM and do it on weekend.

I'd suggest it as a thread but alas... I don't have enough posts to do so.

 

[victhewanderer]

Awesome Work!

Great Job on the DIY. I tried to place an order with Gobi but their lead times are 12-14 weeks. Too long and too expensive. I'm debating on making one as well. you've inspired me (and many others, i'm sure).

 

[TexasTJ]

Great Job on the DIY. I tried to place an order with Gobi but their lead times are 12-14 weeks. Too long and too expensive. I'm debating on making one as well. you've inspired me (and many others, i'm sure).

FYI those lead times are a gross understatement. I received mine after 21 weeks, and that was not from a group buy.

 

[ToyoT4R]

The Jake Rack

 

[RAD4Runner]

Yes, good job!
I like low-profile racks.
I wish I had a neighbor/friend like you

 

[Jake0807]

Well done man! That looks great. I live in Solidworks but I just bought a seat of Fusion, SW is way to expensive for personal use. I'm excited to learn that program and start making some parts.

 

[CrackFox]

Yes I did make the ladder as well (I'm pretty proud it came out so well hehe). Functionality wise though, I may rework it, as it would be nice to have a little more room between it and the back door when climbing those rungs.

As for Gobi, so long as I'm not trying to sell anything resembling their products, I believe I can kindly tell them to leave me alone. I shall build whatever I want for myself.

Jakerunner,
did you do a separate write up for the ladder DIY by chance? if so, can you point me in the right direction? Im not to concerned about the ladder body as much as the getting the liftgate mounts/plates.
Thanks:cheers:

 

[jakerunner]

Jakerunner,
did you do a separate write up for the ladder DIY by chance? if so, can you point me in the right direction? Im not to concerned about the ladder body as much as the getting the liftgate mounts/plates.
Thanks:cheers:

I did not do a detailed write up, I can tell you that it was all a matter of playing with it. I didn't have a tool for bending the plate that wraps around the top of the door, so I welded to strips of flat plate together at an angle, and that was a messy PITA. It was all trial and error getting it to fit, and it still rubs a little bit on opening and closing the hatch. The bottom clamping part is so ugly I don't want to show you! But you can't see it unless the door is open and it serves its purpose.

A year and half out from this project now, and I would have thought I would have almost certainly built another one by now. Truth is, all the little imperfections have become so much less noticeable over time, that unless I sit there and stare at it, it doesn't bother me. Eventually, when I have the time and shop space to really do it right, I'm going to build a new version, and it will rival the craftsmanship of the Gobi racks For now though, I can encourage anyone out there to just go start building. It's gonna take that first revision to figure out what features are important to you anyway, and as long as its structurally sound, don't worry about it being a little rough around the edges.

Cheers,
Jake

 

[Art88]

After months of wanting a Gobi Stealth Rack for my 5th gen, but without the cash for one, I finally pulled the trigger...and built one.

Gobi is kind enough to provide specs on the material their rack is made of on the product page (16 gauge, 1 inch steel tubing) and the length, width, and height. This gave me a good starting point.

I drew it up in Fusion 360 just for kicks, and 3D printed a little model to get a look at it.
View attachment 257026
View attachment 257029

I bought 8 20' lengths of tubing, a sheet of 3/4" expanded metal, and some 6x6x1/4" plates. Also picked up some pre-punched weld tabs for misc mounting points. Total about $180

As for tools, I decided to pick up a pipe notcher from harbor freight ($50). Rather than buy an expensive bending tool, I made my own wooden bending jigs ($10), and they ended up working just as planned. These were mounted on a sheet of plywood and moved around, and I hand bent each piece around them. It gave me a good result for the simplicity, with very little flattening and no kinking issues.View attachment 257028

I had access to a wire welder (much needed when working with the relatively thin tubing)

After getting everything cut, bent, and notched, I tacked it together to make sure everything fit and that I liked how it looked. The hardest part was the feet that connect the rack to the mounting points on the car. It took a lot of trial and error to get the mounting holes to line up.
Once I was sure everything was going to fit, I finished welding and cleaned it up with some grinding.
Planning on a coat of primer, followed by some some spray-on black truck bed liner.
Until that's done, lots of pictures!
Cheers

Looks awesome man I built one and looking to build another one.

 

[Krupky]

An update,

I apologize, I had to pull my design files. After some research, I have realized just how thorough Gobi has been in their intellectual property procurement process (they're maniacal, clearly) and based on how far reaching their patents are, I don't understand how ANY company can build a roof rack of any kind without getting sued by them. Frankly, I think their patents are unacceptably broad, but I'm not the USPTO.

I am a college student, and do not have the time nor money to fight them should they decide I'm hurting their business, and it could be argued that by providing design files, I am. :ybrick:

I still want to put together an open-source roof rack project. For it to be done right, it needs a legal foothold though, to keep contributors safe. If anyone has the resources or knows a lawyer who could help us create something that doesn't infringe on Gobi's patent, and actually get it official "open-source" status to protect it, please get in touch with me.

I am happy to continue to provide info on my build, short of providing drawings or design files. No matter what, more info to come.

Cheers

Firstly, amazing job building and work with the bending jig - so brilliant!! Secondly, maybe you could release your plans so that they have to be on tracing paper and overlapping in a special way like tony stark’s Mark1! Then they couldn’t sue cause the plans would be technically incomplete...

Just a thought. Also I like that yours doesn’t have the name gobi everywhere. I hate over branding.