Question for those who've built roof racks...

[Socco]

What size tubing did you use? And more importantly, what wall thickness?
I'm looking to make a full size rack to primarily hold a spare and mount lights to. I always overbuild the crap out of everything I make, but I don't want it to weight a 1000#.

 

[Bandit Runner]

I'm using 13 gage 1.5" diameter tubing which has a wall thickness of about .095"

Got any plans drawn up for us to see?

 

[Socco]

Got any plans drawn up for us to see?

Haven't put pen to paper yet. Bought one of those HF benders and a tube notcher when they went on sale recently. That's as far as I've gotten to date. I'm picturing something with a shallow basket, angled and notched risers, light mount tabs all 'round and a hoop on the front to protect spot lights or perhaps a light bar. Have any pics of your rack?

 

[jmildoc]

i've been thinking of doing one for a while now. I have seen people use conduit or EMT even, I though about testing that out, for a cheap quick satisfaction also to test my customization skills and to keep it light as well. Looking forward to seeing pics.

 

[Whitson Metalworks]

I would hold off on the conduit or EMT, its galvanized and doesnt like to weld worth a crap. i use 1" .065 on all of my racks and with the sides sort-of like a trellis they are very very sturdy while not being too heavy.

 

[Bandit Runner]

Haven't put pen to paper yet. Bought one of those HF benders and a tube notcher when they went on sale recently. That's as far as I've gotten to date. I'm picturing something with a shallow basket, angled and notched risers, light mount tabs all 'round and a hoop on the front to protect spot lights or perhaps a light bar. Have any pics of your rack?

Sounds like a good plan. My rack isn't completed yet, but here is a pic of what it will look like:

And here is the build thread:
http://www.toyota-4runner.org/3rd-gen-t4rs/125705-bandit-runners-roof-rack-build.html

 

[Socco]

Sounds like a good plan. My rack isn't completed yet, but here is a pic of what it will look like:

Did you use Google Sketch for that?

I would hold off on the conduit or EMT, its galvanized and doesnt like to weld worth a crap. i use 1" .065 on all of my racks and with the sides sort-of like a trellis they are very very sturdy while not being too heavy.

Excellent, Thanks! You saved me from hours of looking, comparing, lifting, humming and hawing at Metal Supermarket. And yeah, EMT esta no bueno.

 

[drabbits]

I would hold off on the conduit or EMT, its galvanized and doesnt like to weld worth a crap. i use 1" .065 on all of my racks and with the sides sort-of like a trellis they are very very sturdy while not being too heavy.

I agree with WMW, conduit / EMT makes for nasty welds and you can get sick breathing this stuff in when it burns off. BUT its affordable enough to test ideas with.

My first rack was made from 3/4" 16 gauge which kept the weight down, yet I'm using 1" now.

 

[jmildoc]

I never said I was going to weld the EMT together guys.
How are you bending the 1" steel though?

 

[Whitson Metalworks]

I use a JD2 Model 3 bender and dies. Works awesome, very good tools.

 

[Bandit Runner]

Did you use Google Sketch for that?

No, ProEngineer