Custom Bed Rack build

So I have started the design process for a new bed rack for my 2014 tacoma RC, I want to turn this into an expedition vehicle, and none of the bed racks made really fit with what I want to do. The basics of this rack is that it needs to hold 2 tires (245/75/R16), 10 to 20 gallons of fuel, and a roof top tent. Feel free to suggest ideas to improve design, and please feel free to critique my design. Also this has roughly the same footprint as All Pros expedition rack for the tacoma, and currently weighs 98lbs if made out of aluminium (idk how true that is, thats what autodesk inventor says), the construction is 1.5" Aluminum tubes with .145 walls.

 

Cool design, only change I'd make would be to tie it to the frame, especially with two tires and a rtt (which I can help with btw) you'll not want to put it all on the sheet metal bedsides.

 

well I was gonna bolt it into the bed rails at least on 2 sides, maybe all 3. biggest reason for 2 tires up top is I want to throw an auxiliary tank where the spare tire is located

 

Bed rails are tied into plastic. Check out my build to see my rack, feet drop all the way into the bed, not intrusive to using it and waaaaay stronger.

 

hmm yeah that is interesting, and definitely a lot stronger, allows for the weight to be distributed through the frame, ill keep that in mind

 

Looks good, I love seeing people using CAD for their DIY projects, it just makes everything better.

One thing for you to consider should you go aluminum (and I am all for it with caveats) is what the weld will do to the aluminum's temper and subsequently it's strength.

http://www.lincolnelectric.com/en-u...to/Pages/aluminum-design-mistakes-detail.aspx

WRT Inventor's weight prediction, it will be pretty darn close. One thing inventor will not account for is the welding filler, therefore the prediction will be on the low end.

 

It is a must IMO.....http://www.tacomaworld.com/forum/2n...acoma-bed-rail-reinforcement.html#post6665700

Bedside metal is WEAK

 

@XXXX very interesting, looks like there tends to be rubbing when any sort of load is on them for prolonged periods of time

@Lost Sheep thanks for the informative link, I actually have not welded before and plan on taking a class at the university on welding various metals, I did know that strength isn't everything, gotta have some give. I know people who think strength=integrity and then when a strong force is administered to their structural member they either shear or shatter (depending on the material) because they believed the strongest material was best vs a material that absorbed the energy by bending a little bit.

 

I honestly don't know why more production bed racks tie into the frame. In my mind its a no brainer. The way mine is designed, If I roll over, that rack plus my roof rack will do a TON of protecting. That coupled with the front hoop of my bumper and my sliders there really should be minimal damage to the body. There isn't a panel that is unprotected by steel tubing.

 

Ok so I have completely redone my rack, although it may not look like it, I have actually made the dimensions correct in this one so it should fit my tacoma bed perfectly or any ta coma standard bed for that matter. I have added 6 mounting points to the bed of the Tacoma which mounts to the frame. I have also adjusted the height of this rack from 18.5 inches to 21 inches so it sits near flush with the top of my cab. I have change the tube size from 1.5" OD to 1 in OD with .133 in walls. I have made a custom jerry can holder as well to hold 4 jerry cans which equates to 20 gallons of extra fuel. This is still a work and progress and I'm sure you'll notice some flaws (like mitering mistakes cause I am having problems with my program not wanting to do what I want it to do ) Feel free to critque this design and ask questions.

Total weight of the rack if made out of 6061 Aluminum is supposedly 80lbs

Total weigh if made from mild steel is supposedly 220lbs

These are a view of the mounting plates for the bed





this is a shot of where the tire/gas can holder would go