DIY: Ultra Low Profile Custom Rack / Crossbars for OEM TE Roof Rails

[boyguan]

Brown Santa arrived. Hardware is here.

C

Cant wait for a finished build

The only thing that really needs any real precision fab is the end brackets. The cross bar material can easily be cut with hand saw or chop saw and the holes tapped by hand.

I thought of doing something similar but just with regular angle brackets. This would not provide the tension strength that you have with the plates.

Great idea and cant wait to see the finished result.

 

[TodiN]

You bet. I have ordered the parts and should be receiving them in the coming days. Stay tuned as I work up the final prototype.

Parts Sources:

http://www.tnutz.com or http://www.8020.net (tnutz is cheaper and their shipping is crazy fast)
http://www.mcmaster.com
Home Depot (misc raw materials, etc)

C

Started to dig more into these web sites. Looks like 8020 has free SW where you can design what you would want to build. tnutz offers precut 10x20x47” for Primsu rack (the same length as SouthernStyleOffroad - measured mine and the cross bars are 47” length). One bar 10x20x47” is $16.25!!!!
This is a gold mine

 

[btcsxj]

Rocking home built rails for factory bases. No big deal. Not exactly the rocket science that you're making it out to be. Disassemble a folding RTT and you will find that the whole tent is secured to the aluminum extrusions by 4 - #10 screws! Simply weld some end plates onto some 1 x 2 x 16ga steel tubing, couple extensions to mount the awning, viola.

Only suckers spend $1500 on a rack only to cover it completely with a tent.

 

[Terrapod]

Rocking home built rails for factory bases. No big deal. Not exactly the rocket science that you're making it out to be. Disassemble a folding RTT and you will find that the whole tent is secured to the aluminum extrusions by 4 - #10 screws! Simply weld some end plates onto some 1 x 2 x 16ga steel tubing, couple extensions to mount the awning, viola.

Only suckers spend $1500 on a rack only to cover it completely with a tent.

Nobody said it was rocket science. Totally agree the prices for roof racks are absurd.

Your solution is certainly interesting. Glad to hear it has worked for you.

While I suppose it could, my solution has nothing to do with a RTT. I need a location to place storage boxes and gear for trips. The tracks in the extrusion will help with securing gear cleanly.

C

 

[007Tacoma]

Looked at those carefully. Since you mentioned them, allow for my unbiased professional critique:


- Design: Functional, but the raised portion versus the side rails is a design miss. Not diggin it... But as they say "...beauty is in the eye...". Slim and trim would be the way to go here. Now...if there was a nice bevel at the end of the crossbar down to the rail...cool. The straight sides with the 1" raised portion does not make me smile. But I also understand why they did it. (Rago's)

- Material: Steel....because it's easy. Looks like 1/8" to 3/16" sheet steel CNC cut and then bent. Cost of materials = cheap, time to produce = cheap.

- Weight: Curious on the total weight of 4 cross bars.

- Cost: $80 per bar? Why not a set?


Lastly...just curious. Is that your grey 4runner on the home page of their site?

I'm not selling anything. I simply make stuff to help folks. When someone offers up a properly made piece with a reasonable profit margin of 30-40%...then I'll not give them a hard time.

C

Just one thing I should mention...
The design of the LFD Bars is why I bought a set. Being that they are raised slightly over the rails means that their tops (and the base of anything you put on them) is above the end caps. So, this means my RTT can be taken off of its aluminum rails and mounted straight to the LFD Bars for a very low profile.

When I don't have the RTT up there, I have a Rhino Rack mesh I can bolt onto them to carry whatever I need/want/shouldn't-have up there without damaging the end caps since the rack/mesh covers them.

...of course, all of this is in theory since my LFD Bars are on their way to me right now, and I will be picking up my Roam Adventure Co RTT after the bars come in...
:behindsofa:

I still really like the idea of the aluminum T-Slot bars. I hope to do this on a trailer build once I have the money to do that. Then I will throw the RTT and the awning on that, and use my roof rack for other trouble. Towable Base Camp? That's my kind of camping.

 

[Terrapod]

Just one thing I should mention...
The design of the LFD Bars is why I bought a set. Being that they are raised slightly over the rails means that their tops (and the base of anything you put on them) is above the end caps. So, this means my RTT can be taken off of its aluminum rails and mounted straight to the LFD Bars for a very low profile.

When I don't have the RTT up there, I have a Rhino Rack mesh I can bolt onto them to carry whatever I need/want/shouldn't-have up there without damaging the end caps since the rack/mesh covers them.

...of course, all of this is in theory since my LFD Bars are on their way to me right now, and I will be picking up my Roam Adventure Co RTT after the bars come in...
:behindsofa:

I still really like the idea of the aluminum T-Slot bars. I hope to do this on a trailer build once I have the money to do that. Then I will throw the RTT and the awning on that, and use my roof rack for other trouble. Towable Base Camp? That's my kind of camping.

Totally cool man. There is no perfect 'one-size-fits-all' when it comes to camping/overlanding. 90% of camping / overlanding reflects a level of personal preference / comfort.

Go to an event and everyone there will have something different that fits their version of the camp. There might be the same "parts", but even the uses will be unique.

C

 

[007Tacoma]

Totally cool man. There is no perfect 'one-size-fits-all' when it comes to camping/overlanding. 90% of camping / overlanding reflects a level of personal preference / comfort.

Go to an event and everyone there will have something different that fits their version of the camp. There might be the same "parts", but even the uses will be unique.

C

Very true! Attending the Texas Avid Outdoors Fall Expo in 2017 opened my eyes to a whole slew of possibilities.

I just figured I would mention that difference in design because it should server my needs very well.

 

[honda250xtitan]

Towable Base Camp? That's my kind of camping.

Yes. I can't wait just be able to hook up the trailer and take off.

 

[Terrapod]

Yes. I can't wait just be able to hook up the trailer and take off.

Ironically, I have been toying with selling the one I just finished. I might even be willing to sell it loaded with all the extras. :hello:

(I am thinking about building/outfitting a Taco or Colorado pickup).

C

 

[Louise]

Not exactly the rocket science that you're making it out to be.

Literally the first thing in his title is "DIY." Not sure how this was interpreted from do-it-yourself to this-is-rocket science.

This sounds like a cool DIY project for those who like to build things. Thank you for sharing your ideas.

 

[JKLNHYD]

For $44/each, the rails are a steal!
www.prinsudesignstudio.com

It's getting the inner adapter plate threaded that might be difficult for someone who hasn't done it before. They would have to resort to finding a shop that could do it.

I started planning a similar idea but used 3/8" carriage bolts that fit the side rail groove perfectly. I just didn't know what I was going to source for the rails themselves until you mentioned the Prinsu ones.

Great job thus far!

 

[Terrapod]

For $44/each, the rails are a steal!
www.prinsudesignstudio.com

It's getting the inner adapter plate threaded that might be difficult for someone who hasn't done it before. They would have to resort to finding a shop that could do it.

I started planning a similar idea but used 3/8" carriage bolts that fit the side rail groove perfectly. I just didn't know what I was going to source for the rails themselves until you mentioned the Prinsu ones.

Great job thus far!

Tnutz has the rails for far less than half that.

Regarding the inner plate - it's ironic. I just found a simple / alternative solution that is pre-threaded.

More to come... (working on the mounting / adapter plates now).

C

 

[KP Texan]

It's getting the inner adapter plate threaded that might be difficult for someone who hasn't done it before. They would have to resort to finding a shop that could do it.

That's why this would be a great project for someone to learn a few things. Unless I've missed some of the main design elements, one could easily make due with some youtube videos and a center punch/proper drill bit/thread tap.

 

[honda250xtitan]

Ironically, I have been toying with selling the one I just finished. I might even be willing to sell it loaded with all the extras. :hello:

(I am thinking about building/outfitting a Taco or Colorado pickup).

C

Wheres the fun in that? I'm a forever tinkererererer. lol

 

[Terrapod]

Wheres the fun in that? I'm a forever tinkererererer. lol

LOL :cheers:

 

[HighTechAddict]

Thanks for the recommendation

well i was responding to the person i quoted who was asking for features the LFD bars offered, no reason for you to be offended

the raised portion that you don't like is important if you ever want to carry something wider than the rack (sheet goods for example). having the bars sit higher also allows you to easily get tools under the bar or pass straps under them, this is difficult to do with the stock bars (and will be even harder with your bars that will sit lower than the factory bars)

you can buy them in a set, and you get to pick what size set you want

Thanks, I appreciate the recommendation. No harm in having other options to look into.

Personally, I really like the idea of a DIY solution, both to have something to mess around with and put my own personal touches on, and even more for lower cost. The less I spend on each individual modification, the more mods I can afford to do. Plus, the tinkering in the garage keeps me off the streets at night

Whether this works out for OP or not and if it would work for my personal needs, I appreciate the effort of trying something a little different and sharing the results with everyone to do what they want with it.

 

[TodiN]

Tnutz has the rails for far less than half that.

Regarding the inner plate - it's ironic. I just found a simple / alternative solution that is pre-threaded.

More to come... (working on the mounting / adapter plates now).

C

Indeed on Tnutz prices:

10x20 white 47" for $16.25: https://www.tnutz.com/product/ex-10...tted-aluminum-extrusion-for-prinsu-roof-rack/

10x20 black 47" for $20.50: https://www.tnutz.com/product/ex-10...tted-aluminum-extrusion-for-prinsu-roof-rack/

 

[STX4Runner]

I'd wonder how much weight or stress only 1/8" of threaded metal could hold. You might think about these bolts. I'm using them on some stuff I've come up with for the stock side rails and really like them.

https://www.mcmaster.com/#5537t271/=1bvcpt2

 

[Terrapod]

I'd wonder how much weight or stress only 1/8" of threaded metal could hold. You might think about these bolts. I'm using them on some stuff I've come up with for the stock side rails and really like them.

https://www.mcmaster.com/#5537t271/=1bvcpt2

Good stuff. I'm saving these. I have actually found a more robust connection in these:

https://www.mcmaster.com/#3259t43/=1bvcwjx

The channel is about 1 3/8". I test fitted one that I have in my parts bin. Works great. Should be a simpler, but stronger clamping force.

C

 

[STX4Runner]

Good stuff. I'm saving these. I have actually found a more robust connection in these:

https://www.mcmaster.com/#3259t43/=1bvcwjx

The channel is about 1 3/8". I test fitted one that I have in my parts bin. Works great. Should be a simpler, but stronger clamping force.

C

How do you hold those in position in the side rail so you can start screwing in the bolt? Do you slide them in from the end with the backing plate and bolt already attached? The nice thing about the t head studs I linked to is they don't require you to remove the caps on the end of the rails. You just insert and twist.