DIY prinsu style shell rack

subd to see if someone makes a roof rack like this

 

Cool! I've been looking for a rail system like this! I would think you could trim. They are aluminum extrusions to would have the same cross section throughout. You might just need to add holes to match up with factory holes in the cab, if you don't want to do any drilling.

 

I'm working on it. Just gotta get the dims correct on the top of my DCSB for the OEM rack.

 

I was gonna try it, i ordered the stuff a few weeks back but that laziness kicked in

 

I just went to your build thread originally to see details on the awning and cap rack. Ended up reading through you entire build from the beginning... only to find no info on those things at the end...lol. Awning deets? Love the wrap around style. Also what rails on the cap rack did you use? Rhino?

But crazy build! Bravo on the 4x4 conversion!

 

AC doesn't have holes so there's drilling no matter what. The ditch channels should have the same cross section but what I don't know is how the curvature in (X,Y) compares to a DC(I know mine curves more on the back half because the clam shell is shorter). I think the best way to check short of dropping 2 bills is to template a DC channel with 1/8" ply and see if I can make the template fit my AC as that would closely approximate the actual process. If it's close enough then it's only a matter of time before my wallet succumbs to the outward pressure. I just need to find someone local and willing to let me spend a few hours next to their truck. Might also check with Calico and ask how well the oem DC roof rack lines up with his AC channels.

 

Thanks. I haven’t updated my thread in a while.

The awning is a Shadow Awn by Alu Cab. It can be setup without poles, so it needs strong mounts and the hinge bracket has to be supported. I made the mounts with 3/16” steel. Not sure what rails you’re referring to.

 

I think he's referring to how the rack mounts to the cab. Or possibly the cross rails instead, hard to tell so maybe I should just pass.

 

I made it just like OP’s. 3”x3/16” aluminum bar for the side rails, the crossbars are linked in the first thread, the feet are 1.5” square tube, and the Thule tracks were on the cap when I bought it.

 

Ahh... I see. Just lurk in a mall parking lot and wait for someone with a double cab to park and go in... haha. i do think though that these channels will have some flex to them though. They look to have pre curve in pics I've seen, but i doubt the curvature is absolutely perfect. They probably depend on being fastened so it think if its close it could work.

If I end up getting these rails I'll check.

 

Yeah sorry, side rails is what I meant to say. Or tracks I realize now is what they actually should be called. Side rails are more the raised type I guess?...

Really good job, looks factory made.

 

Since they're made in many different ways the term "rails" is used several ways so it gets confusing but tracks seem to always be channels mounted to the roof and not all systems use them. So far the rhino ditch tracks look the best to me. More ordinary roof tracks can be installed next to the ditch but I'm leery of that as the sheet metal is only one layer thick and more flexible than the ditch. Apparently it's not an issue though so it's more of an aesthetic thing, I just like the idea that when it's not mounted it looks stock. One other thing is that if the track channel is similar to the extruded aluminum channel used by prinsu and others there's a cover you can get to snap on and keep it from accumulating crap.

 

Rhino Ditch tracks supposedly arriving Friday. Given how long it takes me to finish anything I may be without a head liner for a bit. Especially if I get some noico.

 

Where did you find the Aluminum bar for the sides? I am having trouble finding any ~5-6ft at my local Lowes or Home Depot.

 

I just went to a local metal supply house, Metal Supermarket. Looks like you have one in Nashville.

https://www.metalsupermarkets.com/nashville/

 

Ah thank you man!

 

You can also get the extruded aluminum bars here:
https://www.8020.net/

 

Is $30 for shipping of the TNutz cross members standard? I am looking at $150 for the unpainted cross members and hardware shipped to my door. Seems fairly steep. Is there any where to buy these T-Bars in person?


All-in-all, I estimate about $275 in materials to make this rack. This includes buying the Pro-Line Mounting Track.

 

That’s about right. I’ve got roughly $200 in parts in mine. With 7 crossbars

 

I am spoiled by Amazon Prime and hate paying for shipping so I didn't account for it being so high.