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

[michalik.piotr6837]

FWIW, I put a pair of Yakima cross bars on top of my factory rails, threw a 120lbs Autohome tent up there and my fat almost 200lbs ass and my 100lbs gf been sleeping up there for months with no issues....so roughly 400lbs on the stock bars.

 

[Terrapod]

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.

Awesome stuff. As you guys begin to experiment and put your versions together, please do share on the thread. I'm sure everyone will enjoy seeing the variations.

C

 

[t4r_my_life]

That's a great idea. Thanks for sharing.

 

[4RCrusing]

Here's the new mounting / adapter plate idea. This time, I have added some 3/8" anchor points for tie downs. The idea has potential.

Since I'm still waiting for materials to arrive I've spent a little time taking measurements and doing layout planning. I really like the low profile look and took some measurements to confirm clearance between the roof and bottom of the extrusion bars. Placed a heavy straight piece of bar stock across the rails and was surprise about the curvature of the roof. At the rails there is sufficient clearance but at the center I would only have 1/4" clearance between the cross bar and roof.
So now I understand your revised setup raising the cross bar up another 1/2" or more to gain clearance. I've cut out a few cardboard templates mimicking your revised layout and taped them to the rail and asthedicly it looks good. And I might go that route are something very similar. I also have some quarter round coming and playing with ideas on shaping the end plate to conform to the quater round on the front cross bar or maintain a shape similar to what you have shared. Your eye for proportions is much better then mine, I'll be cutting cardboard templates until I find what I think I like. Hopefully next weekend I'll have materials and the time to fab up at least one bar and share some pictures.

 

[Terrapod]

Has anyone progressed on their versions? I apologize for the delay in mine. Lots of daily grind work lately and I am also prepping the rig and trailer for a trip out to Moab at the end of the month.

Stay tuned.

 

[4RCrusing]

Has anyone progressed on their versions? I apologize for the delay in mine. Lots of daily grind work lately and I am also prepping the rig and trailer for a trip out to Moab at the end of the month.

Stay tuned.

Actually I have, Tnutz finally came through. Three rails installed and all when we'll. will take some pictures. I do have a little wind noise but haven't had time to adjust bar placement to see if that solves the issue. I think it turned out great and look forward to share my spin on your original design. Many thanks.

 

[Terrapod]

Actually I have, Tnutz finally came through. Three rails installed and all when we'll. will take some pictures. I do have a little wind noise but haven't had time to adjust bar placement to see if that solves the issue. I think it turned out great and look forward to share my spin on your original design. Many thanks.

Did you put the 1/4 round on the front of the lead bar? What kind of noise are you getting?

C

 

[4RCrusing]

Did you put the 1/4 round on the front of the lead bar? What kind of noise are you getting?

C

Yes I used the quarter round bar on the front rail. At sixty and above it is a fluttering/buffeting type wind noise similar sounding to if you were to hang something out of the window while driving, sorry hard to describe. It's noticeable but not over bearing. My bars are installed so the center-line of the rail is slightly above the side rail allowing me 3/4" to 1" clearance at the center of the roof and so i could use button head screws, my drill stop doesn't work well enough to countersink and produce the finish i want using flat head screws. I also used 1/4"x 1" x 5 3/4" drilled and tapped bar slid into the rail, that worked quite well. If shifting the bar locations doesn't work I've got a plan to fab and install a fairing. Work has me snowed under but I'll post some pictures this weekend.
I'm really quite happy with the way it turned out.

 

[4RCrusing]

[/ATTACH]here are a few pictures, first time posting files so let's see how this goes. What's the trick to attaching multiple pictures?

 

[4RCrusing]

looks like one at a time on the pictures.

 

[4RCrusing]

clearance of 7/8" from the roof ridges that protude up, about 1-1/4" at the center and 1-3/4" at the side rails.

 

[4RCrusing]

a view from the rear

 

[4RCrusing]

and this is the last one unless someone wants to see anything specific. After I took the photos I moved the front rail forward and then centered the middle one. I'm thinking about building a fourth rail. This is a sturdy setup.
The rails are easy to reposition. If anyone wants more info I'll be glad respond. And thanks goes to Terrapod.

 

[Minneyota]

View attachment 295170 and this is the last one unless someone wants to see anything specific. After I took the photos I moved the front rail forward and then centered the middle one. I'm thinking about building a fourth rail. This is a sturdy setup.
The rails are easy to reposition. If anyone wants more info I'll be glad respond. And thanks goes to Terrapod.

I really like the way this turned out. I've been considering the LFD crossbars but have been watching for updates on this thread. What would you estimate your total cost to be for fabricating these?

 

[4RCrusing]

I really like the way this turned out. I've been considering the LFD crossbars but have been watching for updates on this thread. What would you estimate your total cost to be for fabricating these?

Thanks I'm pleased also and glad Terrapod shared his idea. All in for materials including shipping costs you should be able to duplicate a three bar setup like I did for $135-$145. I have all the tools needed, saw, drill press, files, drill bits and taps, center punch, etc so no cost there and it's pretty basic fab work which I did myself.
You need to be precise on measurements so take your time, make a template to make sure you like the looks and that things fit the way you want and go for it. It's a rewarding project to take on.

 

[4RCrusing]

Want to add that moving the front cross bar as far forward as possible helped eliminate most of the wind noise.

 

[KP Texan]

Want to add that moving the front cross bar as far forward as possible helped eliminate most of the wind noise.

Thanks for the update! I was about to ask that question.

That looks like an awesome setup! Did you use 1/8" aluminum for the end supports? What tools did you use to cut those to size and shape them? Wish I had access to a machine shop that could simply know out a few of those on a water jet table...

 

[4RCrusing]

Thanks for the update! I was about to ask that question.

That looks like an awesome setup! Did you use 1/8" aluminum for the end supports? What tools did you use to cut those to size and shape them? Wish I had access to a machine shop that could simply know out a few of those on a water jet table...

Correct 1/8"x2" on the end plates. I actually cut the end plates and everything else with a miter saw and used a file to finish it off. You could get the same results using a hack saw and a file, it will just take a lot longer. A drill press is also a big help. Good luck if you decide to give it a try.

 

[Dropzone]

i used a lot of info in this thread when i built the rack for my 2nd gen.
I found that you can buy 145" (12') sections from Fastenal.com very reasonable.
If you have one of their stores near your location you can have them shipped straight to your local fastenal very cheap. if not shipping can be every expensive.
Pricewise it works at a little cheaper than ordering the precut pieces from tnutz.com by the time you pay for UPS shipping.

Tnutz had awesome customer service and warp speed shipping for the brackets and inserts.

My local Ace Hardware was the go to source for bulk purchase of stainless 1/4-20 stainless bolts

Progress Report:



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

[MENTION=148699]Terrapod[/MENTION]: did the 1/4 round help reduce the wind noise?
I have a slight whistle on the rack I built.
Thanks for your time

 

[Terrapod]

[MENTION=148699]Terrapod[/MENTION]: did the 1/4 round help reduce the wind noise?
I have a slight whistle on the rack I built.
Thanks for your time

A trip to Moab and some work related travel has pulled me away from my project. However, I think one of the others did use the 1/4 Round.

I hope to get back on this ASAP.

C