DIY: Ultra Low Profile Custom Rack / Crossbars for OEM TE Roof Rails
- Thread starter Terrapod
- Start date
Thanks OP, I've been looking for a clean and professional looking DIY alternative for some crossbars. In my case these would work fine, I really don't need crossbars but more a matter of want. And I like to tinker.
Really look forward to see how you address the final mounting of the bar to the rack as well as mating the quarter round to the crossbar.
This is great stuff!
Really look forward to see how you address the final mounting of the bar to the rack as well as mating the quarter round to the crossbar.
This is great stuff!
Terrapod
New member
Been a busy, rainy Sunday.
Progress Report:
Overall the rails are working as designed. I hit a slight speed bump - the threaded channel nuts are exactly 1mm too large. I am working towards getting alternative nuts (thinner) or something different all together. I have not yet ruled the original idea of a 5/16 threaded 1" bar. stay tuned.
In the meantime here are the fabrication and assembly photos:
Please note - I have not cleaned up the mounting adapters. I am planning to lightly sand them, take off all burrs and round the corners.
1) Bars cut to length @ 40.25" (measure your truck's rail to be sure.)
Note - I decided to make the leading one to be a bit more aerodynamic and went with a piece of 1" quarter round
2) DISREGARD THIS - SEE POST #86: I carefully measured the height of center point of the stock side rails (5/8") and the centerline of the crossbars (1/2"). The carefully measured the centers of each drill hole and drilled them out on my drill press. The crossbars are 1/4" the sides are 5/16". The 3, 1/4" holes were then countersunk to match the height of the 1/4" flat head bolts.
Once the ends of all the crossbars were tapped with a 1/4-20 tap, I then assembled them:
Then loosely fit the 5/16" bolts:
the Problem: the channel nuts are slightly too thick (by approx 1mm). I am either going to grind them down (tedious) or make the original 1" bar and tap it with a 5/16" tap.
Here is the test fitment - so far so good:
Progress Report:
Overall the rails are working as designed. I hit a slight speed bump - the threaded channel nuts are exactly 1mm too large. I am working towards getting alternative nuts (thinner) or something different all together. I have not yet ruled the original idea of a 5/16 threaded 1" bar. stay tuned.
In the meantime here are the fabrication and assembly photos:
Please note - I have not cleaned up the mounting adapters. I am planning to lightly sand them, take off all burrs and round the corners.
1) Bars cut to length @ 40.25" (measure your truck's rail to be sure.)
Note - I decided to make the leading one to be a bit more aerodynamic and went with a piece of 1" quarter round
2) DISREGARD THIS - SEE POST #86: I carefully measured the height of center point of the stock side rails (5/8") and the centerline of the crossbars (1/2"). The carefully measured the centers of each drill hole and drilled them out on my drill press. The crossbars are 1/4" the sides are 5/16". The 3, 1/4" holes were then countersunk to match the height of the 1/4" flat head bolts.
Once the ends of all the crossbars were tapped with a 1/4-20 tap, I then assembled them:
Then loosely fit the 5/16" bolts:
the Problem: the channel nuts are slightly too thick (by approx 1mm). I am either going to grind them down (tedious) or make the original 1" bar and tap it with a 5/16" tap.
Here is the test fitment - so far so good:
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Terrapod
New member
PROJECT UPDATE:
Overall, I consider this a success. However, it needs some fine tuning.
Challenge #1 - The Channel nuts are a PITA. They work (after grinding)...but they get bound up in the side rails. Solution: More grinding? Perhaps. Thing is, I am also grinding off the protective zinc coating.
Challenge #2 - in order to get the crossbar on cleanly, I had to loosen the side rails. Upon doing so, the bar clearance changed. Even upon tightening everything back up, the dimension changed. Solution: I am going to fabricate slightly different adapter plates that raise the cross bar up by about 1/4 to 1/2". Yes, they will be slightly above the side rails, but I think the design solution in my head will make them pleasing to look at.
This is really close. More to come.
Really digging the clean look. (finished look - burrs taken off, corners rounded and surface given a light sand for appearance).
Overall, I consider this a success. However, it needs some fine tuning.
Challenge #1 - The Channel nuts are a PITA. They work (after grinding)...but they get bound up in the side rails. Solution: More grinding? Perhaps. Thing is, I am also grinding off the protective zinc coating.
Challenge #2 - in order to get the crossbar on cleanly, I had to loosen the side rails. Upon doing so, the bar clearance changed. Even upon tightening everything back up, the dimension changed. Solution: I am going to fabricate slightly different adapter plates that raise the cross bar up by about 1/4 to 1/2". Yes, they will be slightly above the side rails, but I think the design solution in my head will make them pleasing to look at.
This is really close. More to come.
Really digging the clean look. (finished look - burrs taken off, corners rounded and surface given a light sand for appearance).
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mgproudfit
Member
So is your thought process that once the bars in place that they'll rarely, if ever, be moved? If not, it seems like an enormous PITA to adjust the hex-head screws frequently. That said, I may be misinterpreting the functional aspect.
Terrapod
New member
Not sure I follow. The bars are designed to be adjustable fore and aft. Simply loosen the two 5/16" hex bolts and slide the bar.
Terrapod
New member
I simply use a multi-use blade on a chop/mitre saw. That's one of the benefits of aluminum. Just make sure the blade is for wood/metal/plastic, etc
C
Hi Terrapod,
I like your low profile approach. I made something similar, using mounting blocks to interface between the factory rails and the t-slot extrusion that extends past the rails 6 inches. Although not nearly as elegantly low profile as yours, it works quite well for me.
Do you get much wind noise? I get a little bit at 60 MPH, and I'm keeping an eye out for a solution.
I like your low profile approach. I made something similar, using mounting blocks to interface between the factory rails and the t-slot extrusion that extends past the rails 6 inches. Although not nearly as elegantly low profile as yours, it works quite well for me.
Do you get much wind noise? I get a little bit at 60 MPH, and I'm keeping an eye out for a solution.
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Love the design that’s gone into this.
I already have clearance issues with attachments for my factory bars. With this it would allow me to use my own design to mount some items.
Terrapod
New member
Nice work. And...thank you. Not quite there to test wind noise yet. Today was fabrication day. Stay tuned.
mgproudfit
Member
Yea, that's essentially what I was getting at. Seems to me adjusting the hex bolts would be a PITA to move the bars around unless once you have the bars "in place" they don't need to move much.
"Really digging the clean look. (finished look - burrs taken off, corners rounded and surface given a light sand for appearance)."
Me to, awesome work. I'm sure if you go with the alternate plate design it will also look good and obviously provide a little more clearance and I'm guessing the crossbar bolts will be exposed allowing the bar to be removed easily in case a few more t-nuts need to be added.
Regardless you've got my interest and T-Nuts got an order for some 1x3's. Thanks for sharing and good luck I've got the feeling quite a few will be following your lead.
Me to, awesome work. I'm sure if you go with the alternate plate design it will also look good and obviously provide a little more clearance and I'm guessing the crossbar bolts will be exposed allowing the bar to be removed easily in case a few more t-nuts need to be added.
Regardless you've got my interest and T-Nuts got an order for some 1x3's. Thanks for sharing and good luck I've got the feeling quite a few will be following your lead.
e60ral
Banned
Get the peices that snap into the track, that will help your wind noiseHi Terrapod,
I like your low profile approach. I made something similar, using mounting blocks to interface between the factory rails and the t-slot extrusion that extends past the rails 6 inches. Although not nearly as elegantly low profile as yours, it works quite well for me.
Do you get much wind noise? I get a little bit at 60 MPH, and I'm keeping an eye out for a solution.
Sent from my SM-G930V using Tapatalk
Hi Terrapod,
I like your low profile approach. I made something similar, using mounting blocks to interface between the factory rails and the t-slot extrusion that extends past the rails 6 inches. Although not nearly as elegantly low profile as yours, it works quite well for me.
Do you get much wind noise? I get a little bit at 60 MPH, and I'm keeping an eye out for a solution.
Looks good and stout. It looks like you fabricated an aluminum bar, drilled and threaded to accept the bolts from your riser. What size bar did you use and did it slide inside the factory rail without issue?
I used .25 x .75 inch 6063 aluminum for my backing plates, because I happened to have some on hand. But you could fit .375 x 1 in the slot if you wanted. With 3 M6 bolts per riser, there is plenty of clamping pressure and I haven't had any slipping or thread damage at .25 thick. I pre-assemble, slide each riser into place, then tighten down.
I thought I'd share what I did because it is so similar to what Terrapod is building, but I don't want to highjack the thread. Please shoot me a PM if you have any specific questions - happy to share.
I thought I'd share what I did because it is so similar to what Terrapod is building, but I don't want to highjack the thread. Please shoot me a PM if you have any specific questions - happy to share.
Thanks for the response, I'm in the process of gathering materials while waiting for the T Nutzs rail delivery. I have some 1/4"X1" flat bar on hand so will most likely use that, thanks for confirming it will work.
Terrapod has done a great job so far documenting his design and build and looking forward to seeing the finished project.
