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My cargo crossbar build

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Old 12-12-2009, 05:34 PM   #1
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My cargo crossbar build

Well sort of. Sorry I didn't take pics during the process, but you will get the idea.

Materials:
1x 10ft 3/4" rigid conduit
1x 1/2"-3' steel tubing stock
1x 1/8" thick, 1 1/2" x 3' steel flat stock
8x 1/4-20 flat washers
8x 1/4"x 3" hex bolts
8x 1/4" fender washers
8x 1/4" lock nuts
1x Rustoleum Undercoating spray paint

Tools:
Grinder
Something to cut steel
Somekind of low amperage welder(or you will burn through the tube stock)
7/16 wrenches
Helper

First, I built the pieces that mount to the cleats in the bed. I cut the flat stock into four, 4" lengths. Also cut 8 pieces of 1 1/2" lengths of tube stock. I went a little over that way I could grind everything down evenly. Mark and weld the tube stock onto the flat stock.(I mounted the tube stock pieces onto the cleat with the nuts and bolts. Then placed the flat stock up to the tubes to figure out where the welding needed to be.) Do this for all cleats.


Then I installed all cleats with crossbar mounts onto the truck. Now for the tricky part. The distance between the mounts was about 53 1/2". I went over so I could grind down the conduit to get a snug fit. When you get it snug, weld the conduit to your mount like the pic below.



Now for painting. I used Rustoleum Undercoating spray paint. It worked perfect.

When everything is dry, mount it. Here is the hardware setup I used.

Finished product.



I initially intended to mount the bars under the cleats. But with the snowboards on the rack the tailgate wouldn't close. Damn shortbeds.
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Old 12-12-2009, 05:44 PM   #2
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impressive... looks like a commercial rack...
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Old 12-12-2009, 05:47 PM   #4
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looks really nice man.
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Old 12-13-2009, 02:11 AM   #5
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I thought about doing something like this for a spare tire rack in the bed.
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Old 12-13-2009, 08:55 AM   #7
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That is a great mod!
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Old 12-13-2009, 09:07 AM   #8
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Quote:
Originally Posted by FoxTaco View Post
I thought about doing something like this for a spare tire rack in the bed.
You could definitely do that. The 3/4" rigid conduit is very strong.
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Old 12-13-2009, 09:15 AM   #9
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Nice action. You could use those for many different cargo apps.....
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Old 12-13-2009, 09:26 AM   #10
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AAhhhh the epitome of simlicity, yup, ya get my vote...good, quick, and slick.
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Old 02-18-2010, 02:36 PM   #11
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Sweet idea! How would you suggest doing this to a 1st gen?
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Old 02-18-2010, 02:38 PM   #12
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^^Do you have bed cleats? If so same parts, just different measurements.
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Old 02-19-2010, 05:52 AM   #13
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Quote:
Originally Posted by Zac808 View Post
^^Do you have bed cleats? If so same parts, just different measurements.
Nope no bed cleats. It would be a lot nicer if i did. I wonder if I can take the bed cleats off a 2nd Gen from a junkyard and install them in my bed. I'm sure I can...

Thanks
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Old 03-01-2010, 05:35 PM   #14
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how much weight can you put on the cleats? i really like this idea.
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Old 03-01-2010, 05:37 PM   #15
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nice rack. I wanna build something that can mount my bikes but still allow me have my roll-up tonneau cover.
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Old 03-01-2010, 09:26 PM   #16
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Quote:
Originally Posted by macgyver View Post
nice rack. I wanna build something that can mount my bikes but still allow me have my roll-up tonneau cover.
You could mount the crossbars to the bottom of the cleats.
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Old 03-01-2010, 09:32 PM   #17
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Nice job!
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Old 03-02-2010, 08:02 AM   #18
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Quote:
Originally Posted by Zac808 View Post
You could mount the crossbars to the bottom of the cleats.

let me clarify, I want to be able to have my tonneau cover closed and have the bikes on top. That way I can still retain the bed of the truck for gear. Right now I have my fork mounts mounted to the front tracks and have to roll up my tonneau cover to put the bikes in the bed so I essentially I loose some use of the bed depending on how many bikes I have in there.
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Old 03-02-2010, 11:38 AM   #19
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Quote:
Originally Posted by Hunter'06FLKY View Post
how much weight can you put on the cleats? i really like this idea.
I think the cleats are rated at 200 pounds
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Old 03-07-2010, 01:16 PM   #20
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Mine

http://www.tacomaworld.com/forum/2nd...ml#post1511704
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My cargo crossbar build-img_3198-2-medium-.jpg  
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