I built a Prinsu Style Roof Rack for $300 - Here's the How-To

Okay I think I’m gonna pull the trigger on doing this after your inspiration.

I need to find a local spot to find 1/4” aluminum in 2”x 8’. Metal Depot is 69 for the aluminum, 109 to ship it.

Home Depot had 1/8 strips in 2”x 8’. No 1/4”

Looks like hardware wise it’s gonna be 60 shipped for everything from McMaster-Carr, including the 1/4 3”x3” angle aluminum for the legs.

The cross bars are going to be $252 shipped.

One thing never brought up was what you made to wind deflector from and what hardware you used in the slots to mount the wind deflector. Thanks again!
 
Interesting, if I plug in Quantity 4: 1/4 inch thick, 2 inch x 4 feet. the shipping goes down to $5, from $109 to just do Qty 2 8 feet length.

I wasn't planning on splitting it in 2 like you did to take up less room if I wanted to store somewhere, wanted to have 92" side plates the whole way through, but not paying that much for shipping.
 
Interesting, if I plug in Quantity 4: 1/4 inch thick, 2 inch x 4 feet. the shipping goes down to $5, from $109 to just do Qty 2 8 feet length.

I wasn't planning on splitting it in 2 like you did to take up less room if I wanted to store somewhere, wanted to have 92" side plates the whole way through, but not paying that much for shipping.

I tried midweststeelsupply.com . 6061 aluminum plate 0.25" - $25.04 per plate - $50.08 for 2. Ground shipping $27.43
 
I tried midweststeelsupply.com . 6061 aluminum plate 0.25" - $25.04 per plate - $50.08 for 2. Ground shipping $27.43

Funny, plugging in same specs I get 25.99 per plate. $189.10 ground shipping :/

Edit: This is doing 1/4"x 2", 2 8 feet pieces.
 
Funny, plugging in same specs I get 25.99 per plate. $189.10 ground shipping :/

Edit: This is doing 1/4"x 2", 2 8 feet pieces.

There is always Amazon: $90.40 + $30.80 shipping for 2 - 6061 T6 Aluminum Bar - 1/4" x 2" x 96"
 
Okay I think I’m gonna pull the trigger on doing this after your inspiration.

I need to find a local spot to find 1/4” aluminum in 2”x 8’. Metal Depot is 69 for the aluminum, 109 to ship it.

Home Depot had 1/8 strips in 2”x 8’. No 1/4”

Looks like hardware wise it’s gonna be 60 shipped for everything from McMaster-Carr, including the 1/4 3”x3” angle aluminum for the legs.

The cross bars are going to be $252 shipped.

One thing never brought up was what you made to wind deflector from and what hardware you used in the slots to mount the wind deflector. Thanks again!

If you have a metal supply store in town it might be cheapest. We have IMS in Los Angeles that is great for this sort of stuff.

I made the wind deflector out of aluminum that was 6" wide and I think something like 1/16" thick. It was like $20 I think

Consider getting 3003 aluminum. It is cheaper and has great corrosion resistance. It is about half the strength of 6061 but at 1/4"x2" you're not going to have a problem. I'd stick with higher strength on the feet though.
 
Does anyone have the dimensions of the stock rails? (Height of the rail, bottom to "slot", height of "slot", "slot" to top of rail) i'm toying with the idea of making cross bars for the stock rack using the info here as a guide, but find myself on the road for work.

Roof Rail Channel Dimensions

Hope it correct.
 
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Does anyone have the dimensions of the stock rails? (Height of the rail, bottom to "slot", height of "slot", "slot" to top of rail) i'm toying with the idea of making cross bars for the stock rack using the info here as a guide, but find myself on the road for work.

Roof Rail Channel Dimensions

Hope it correct.

If you are considering just crossbars, have you seen this thread?

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

That is what ended up doing, but may end up going in the direction of this post.
 
My DIY rack

[MENTION=436994]SuperfastMatt[/MENTION] inspired me to build a roof rack for my 4runner. I used the same materials as he did. I spent close to $500 since I had to buy everything online. Shipping costs add up quick! Here are some pics.
 

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I literally just watch this video yesterday. Great video and gives me lots of ideas.

One of my concerns is wind noise. What was the permanent fix for the wind noise?
 

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