New DIY aluminum platform rack for factory rails

[Off2Mtns]

I realized I could throw something together for about the cost of a set of factory cross bars, so I ordered some material to tinker with. Took some inspiration from a majority of the racks around and came up with what I think is a sleek design. Planning to reuse the factory rails for simplicity sake. I could not get over the “homebuilt” look of just using 2x1 channel in a normal vertical orientation until an idea struck me to rotate it 30 degrees. I think that one subtle change really works to compliment the lines of the factory rails well, but curious to hear other opinions/perspectives.

Going to add 4-6 cross bars and admittedly, the wind fairing is mostly to have a small place to put stickers! Being 1/8” thick aluminum, should weigh in about 25 lbs all said and done.

 

[WhiteWashSurfer]

I like it! The only thing I would change is making it black along with the factory rails.

 

[TOPTEAM]

Looks good...How is it mounted to the stock rails? Any close ups of the mounting?

 

[Off2Mtns]

I'll be bolting to the brackets I built for my Coleman basket: http://www.toyota-4runner.org/2745779-post56.html

[MENTION=144051]b407driver[/MENTION], thanks for the inspiration… you saved me about $100 having to buy a set of cross bars to mount my Coleman roof basket!! Fabbed a quick set of brackets out of some 1/4" alum angle. Lest anyone copy the dimensions, keep in mind these are NOT FOR A ROLA RACK!! My Coleman basket measures 39” wide, which I imagine is close though.

In looking at factory cross bars on Amazon some months ago, I read one reviewer who suggested using a paint lid opener to pop off the end caps. BRILLIANT!!

Punched some 3/8” wide slots in a piece of 1/8” x 1” aluminum flat bar to use with some carriage bolts in the factory rails.

Installed.

 

[violation]

that is seriously cool, man!

 

[Off2Mtns]

Rack done, just needs paint. I like how it turned out. Forgot to put it on a scale before install, but should weigh right about 30# and add no more than 2” to overall height. 66” long by 48” wide at extents, about 4” less in either direction of usable area. Dead silent on the road, no more wind noise than I get from my tires.

The 1” straps running fore to aft are pitched slighty to match factory rails and welded to cross bars to make for easier install alignment and aid in distributing weight from the cross bars to factory rails.

The wind fairing is a piece of 16ga aluminum contoured to match the roof line with about a 1/4" gap. Had some silver metallic scrap at work that is about a perfect match to the factory silver trimmings (roof rails, wheels), still debating powdercoating the whole rack that color for a bit more OEM look; otherwise, it will get the typical black treatment. Using the punched slots in the cross bars for a nice low-pro mounting solution using carriage bolts.

Will need to make something a little bigger for my new roof top tent, but will probably do something similar and retain this for the other 95% of the time the tent is in storage.

 

[samwhich]

Rack done, just needs paint. I like how it turned out. Forgot to put it on a scale before install, but should weigh right about 30# and add no more than 2” to overall height. 66” long by 48” wide at extents, about 4” less in either direction of usable area. Dead silent on the road, no more wind noise than I get from my tires.

The 1” straps running fore to aft are pitched slighty to match factory rails and welded to cross bars to make for easier install alignment and aid in distributing weight from the cross bars to factory rails.

The wind fairing is a piece of 16ga aluminum contoured to match the roof line with about a 1/4" gap. Had some silver metallic scrap at work that is about a perfect match to the factory silver trimmings (roof rails, wheels), still debating powdercoating the whole rack that color for a bit more OEM look; otherwise, it will get the typical black treatment. Using the punched slots in the cross bars for a nice low-pro mounting solution using carriage bolts.

Will need to make something a little bigger for my new roof top tent, but will probably do something similar and retain this for the other 95% of the time the tent is in storage.

Great work!! Cant wait to see it painted and mounted up!! Watch out, your inbox may be blowing up soon with order requests :wink2:

 

[2barevo]

Will need to make something a little bigger for my new roof top tent, but will probably do something similar and retain this for the other 95% of the time the tent is in storage.

Great work. When are you accepting orders?

 

[Off2Mtns]

Thanks guys! Sorry, won't be building any to sell.

 

[Off2Mtns]

All done, I like it. Found a silver metallic at the powder coater that is nearly an identical match to the factory silver trim and silver metallic sheet metal fairing; it is slightly darker in low light, but darn close enough!