DIY unistrut roof rack

[4Runrrun'n]

Yup Great! Helps to know your hind sight opinions on the build.
Thank you

 

[TrdLtly]

Thanks [MENTION=86238]4Runrrun'n[/MENTION], I don't plan on putting anything "heavy" up there to keep the center of gravity low when on the trails. Having said that I would make some changes if I were to do it again.
1.) I used the smaller unistrut which is around 1" tall and I believe only 14 gauge. I wish I had used the heavier 1.5"/12 gauge unistrut which would have made it substantially stronger.
2.) I would have mounted it 1/2" higher on the stock rack. This would allow for any flex that did occur to heavy items on the rack.
3.) The unistrut is galvanized and I cleaned with prep prior to painting but it chips easily when scuffed.
Hope that helps.

For reference for others later on that are too lazy to bother to read.... you may want to update your first post with the "suggested" heavier Uni-strut as a lessons learned.

I am also considering looking at adding a wire mesh. I wonder if the wire mesh along with the lighter gauge Uni-strut would suffice? The mesh would add rigidity if bolted to it.

I am with you on mounting it about a 1/2" higher as I would want to be able to put my Thule Atlantis 1800 on it when needed.

 

[llennium]

For reference for others later on that are too lazy to bother to read.... you may want to update your first post with the "suggested" heavier Uni-strut as a lessons learned.

I am also considering looking at adding a wire mesh. I wonder if the wire mesh along with the lighter gauge Uni-strut would suffice? The mesh would add rigidity if bolted to it.

I am with you on mounting it about a 1/2" higher as I would want to be able to put my Thule Atlantis 1800 on it when needed.

Thanks for the suggestion I'll update the first page. I'm sure the wire mesh would help strengthen the rack. Also, if you mount the Thule Atlantis next to the stock rack the lighter gauge unistrut would handle the load depending on what you put inside. I have mounted a full scepter water can up there which I believe is around 40 pounds full and had no flex.

 

[boyfester]

I really like this rack. If you flipped the angle iron by 180 degrees would you be able to raise the rails by the 1/2" that you're looking for?

 

[Ruthven13]

That looks great and is something I would love to do. Unfortunately it also looks like it would be a pain to clean off the snow in the winter. Otherwise looks just like something I would want...

 

[llennium]

I really like this rack. If you flipped the angle iron by 180 degrees would you be able to raise the rails by the 1/2" that you're looking for?

[MENTION=90288]boyfester[/MENTION], flipping the angle would gain 1/2" maybe a little more. It would also lose the finished look on the ends as you would see raw unistrut. It may create even more wind noise.

That looks great and is something I would love to do. Unfortunately it also looks like it would be a pain to clean off the snow in the winter. Otherwise looks just like something I would want...

[MENTION=134289]Ruthven13[/MENTION], It did make cleaning the snow off this year a little harder. Fortunately we don't get that much snow in Arkansas so not much of an issue. Also, if I know the snow is coming I can lay a piece of cardboard up there and pull it off with the snow.

Thanks for the kind words gentlemen, it was a fun project. I'm trying to decide if I want to beef it up to become more useable or look at something like the Prinsu rack.

 

[Hapkijo]

Great job, i'm thinking of doing this, i wonder how it holds up to vibration. I'm pretty certain you need tread lock.

 

[llennium]

Great job, i'm thinking of doing this, i wonder how it holds up to vibration. I'm pretty certain you need tread lock.

@Hapkljo I used nylon lock nuts on everything and haven't had any issues. I do agree if regular nuts were used with no lock washers it would require thread locker.

 

[Hapkijo]

@Hapkljo I used nylon lock nuts on everything and haven't had any issues. I do agree if regular nuts were used with no lock washers it would require thread locker.

[MENTION=23427]llennium[/MENTION] I went out and got some Superstrut, and the parts needed. Going to give this a go. Let you know how it works out.

 

[eferraro]

So I went out and look at the larger 12 gauge uni-strut. I see and issue with the size the it is 1 5/8" vs the 1 .5" height of the my 2016 4Runner rails. I was thinking maybe using expanded mesh below the 14guage uni-strut to give it a bit more rigidity as well as maybe distribute the weight around. Another option may be to use angle bar all around and run some strips of thicker steel bar underneath the uni-strut. IF anyone has any other thoughts or suggestions.