Kraze's Custom Roof Rack Build by drabbits

[drabbits]

I have wanted to share this with all of you for awhile and finally I can.
[MENTION=91297]Kraze[/MENTION] and I agreed on a new custom roof rack that would not only fit six, 6" LED's perfectly in height and width but also with a cage similar to [MENTION=55891]Bandit Runner[/MENTION]. This rack is also being shortened by 1" on top to accommodate his new 36" LED light bar!
Aside from this being a custom job, I wanted to share a build like this to inspire others and to present my work for those members that have inquired into purchasing a roof rack from me.
http://www.toyota-4runner.org/sale-t4r-items/146262-fs-full-length-roof-rack-3rd-gen-late-2nd.html
Feel free to PM me if you ever need help on your own build.
Lets begin :guitar2:

As with all great things ever invented, copied or innovated, they began as a drawing on a napkin of some sort, even the one we wipe our... with. Make use of moments of inspiration where ever they take place!

Day 1.
Get your material, assuming you made measurements. Always get extra, no exceptions.

Thats it for tonight, I'll be posting updates everyday till doneop2:
Laters members

 

[dtc81]

Looking forward to what you come up with! Is that a Handler 140 on a Harbor Freight welder cart? Looks identical to my little set up haha

 

[Bandit Runner]

Cool! Can't wait to see some progress. What size tubing are you using?

 

[Kraze]

Well this certainly looks like it's going to be epic! I might be biased though :biggrin1:

 

[LittleCaesar]

This looks to be quite nice. Spiders love them hollow roof rack rails so button them up tight.

 

[Kraze]

This looks to be quite nice. Spiders love them hollow roof rack rails so button them up tight.

We weren't going to reveal this rack's super secret weapon just yet, but since you bring it up, I guess we can let the cat out of the bag early.

The rack will have 360 degree foggers, shooting a mixture of gasoline and Raid spider killer out of them. We're putting the mixture in the wiper fluid tank, and running the tubing up through the rack. There will be igniters on each spout, so I'll be able to have a full 360 degree fireball of spider killing awesomeness around me at all times when I'm night wheeling! :flamethrwoer2::spider:

 

[LittleCaesar]

I hope pictures will be forthcoming. That will be one mighty cool setup.

 

[drabbits]

LOL! Right on, twins. Yeah its a 140 and H/Fright:0 cart, had to chop and mod it a bit to get it the way I wanted. Cheaper than scrap metal prices!
BTW they came out with a new 140 with more settings.

Looking forward to what you come up with! Is that a Handler 140 on a Harbor Freight welder cart? Looks identical to my little set up haha

 

[drabbits]

Day 2
Measure twice cut once.
Lower and upper rails bent up, upper rail not pictured.
Todays Tip: If you are using 1" OD tubing, use a slightly larger tubing with 1" ID (inner diameter) to connect ends. This gives you 1/16" to 1/4" play to get the width just right.

Here's a rough mock up of whats to come

End of Day 2
BTW, Half rack almost done.

 

[GhostRing]

looking good - why not use a smaller ID tube inside the 2 halves so you can weld & sand smooth?

 

[Ol'Blue]

We weren't going to reveal this rack's super secret weapon just yet, but since you bring it up, I guess we can let the cat out of the bag early.

The rack will have 360 degree foggers, shooting a mixture of gasoline and Raid spider killer out of them. We're putting the mixture in the wiper fluid tank, and running the tubing up through the rack. There will be igniters on each spout, so I'll be able to have a full 360 degree fireball of spider killing awesomeness around me at all times when I'm night wheeling! :flamethrwoer2::spider:

Since you have been a stand up guy I'm going to get this for you as a thank you gift for all the good times. I'll even get a little cage for him so you can put it in the house.

Blue

 

[Whitson Metalworks]

looking good - why not use a smaller ID tube inside the 2 halves so you can weld & sand smooth?

this is what I do, just my preference i guess; using a 7/8" DOM "slug" to join the two. its one of the biggest PITA's of the process! Unless using DOM tubing, your 1" will have an ID of between 7/8" and just enough under 7/8" that a sledge hammer couldn't drive the slug in lol. So, every slug gets turned down by half a smidge. I dont weld them though since welding heat still pulls and tweaks the alignment even with a ridiculously tight fit.

what bender are you using there?

 

[shmabs]

Material

What material are you using?

Mike

 

[drabbits]

looking good - why not use a smaller ID tube inside the 2 halves so you can weld & sand smooth?

this is what I do, just my preference i guess; using a 7/8" DOM "slug" to join the two. its one of the biggest PITA's of the process!

what bender are you using there?

Thanks GhostRing,
In the past I have welded tubing flush with a slug and without, both techniques are, as Whitson put it "a PITA". Using a sleeve has reduced the amount of migraine pills needed and its also become a personal preference of aesthetics.

Whitson,
Its an honor to have you involved man, I'm currently using Pro-Tools. But I have my eye on a all hydraulic JD2 conversion... a blurry eye, one day.

 

[drabbits]

What material are you using?

Mike

Hey Mike,
I'm using A513 tubing, how the mounts coming along?

 

[drabbits]

We weren't going to reveal this rack's super secret weapon just yet, but since you bring it up, I guess we can let the cat out of the bag early.

The rack will have 360 degree foggers, shooting a mixture of gasoline and Raid spider killer out of them. We're putting the mixture in the wiper fluid tank, and running the tubing up through the rack. There will be igniters on each spout, so I'll be able to have a full 360 degree fireball of spider killing awesomeness around me at all times when I'm night wheeling! :flamethrwoer2::spider:

Duuude, are you freakin kidding! This would be awesome, I know some people that just might build something like this for s** and giggles. :rockon:

 

[Whitson Metalworks]

I have my eye on a all hydraulic JD2 conversion... a blurry eye, one day.

JD2 is the way to go! I bit the bullet back when and got the bender and the notchmaster, zero complaints, they are what they say they are for sure. it just sucks buying those die sets at 200-300 each.

 

[kenski]

We weren't going to reveal this rack's super secret weapon just yet, but since you bring it up, I guess we can let the cat out of the bag early.

The rack will have 360 degree foggers, shooting a mixture of gasoline and Raid spider killer out of them. We're putting the mixture in the wiper fluid tank, and running the tubing up through the rack. There will be igniters on each spout, so I'll be able to have a full 360 degree fireball of spider killing awesomeness around me at all times when I'm night wheeling! :flamethrwoer2::spider:

Clearly, you haven't thought this through yet.

 

[Kraze]

Lol. The 360 degree fireball of death was definitely not serious, although I must admit, while I was typing it out, I couldn't help but nod my head and think about how badass it would be to have something like that. But the truth is, I'm just not responsible enough to have that sort of power at the touch of my fingertips. I'm sure I would be tempted to "test it out" on the freeway whenever someone would tailgate me in the slow lanes :flipoff:

So no, no 360 degree fireball of spider killing awesomeness, but this rack will have enough lighting that I should be able to see the spiders coming, so there will be no more sneak attacks :thumb:

 

[shmabs]

Hey Mike,
I'm using A513 tubing, how the mounts coming along?

No progress yet, working on a front skid first. I'm thinking that a total roof rack re design might be in order....


Mike