Custom Cross bars build help square tube sizing

I am looking to build custom cross bars out of square tubing 1.5" or 2" I am looking for some insight on what the thickness of the square tube should be. I am doing just two individual cross bars not connecting them other then the RTT itself linking them together. Making them like this makes the cross bars easier to store when they are not on the truck.

56" is the length I want to run across the bed

20" for each of the four legs

Would would be the most cost effective size tube and that can hold the weight of the RTT and two people in it?

I have the relentless cross bars tall and would be using the same concept just with square tubing and making the bars sit at the roofline

 

Go online and you can find all sorts of data on tubing sizing and weight. As for what will hold the weight of a fictitious RTT and 2 fictitious people is pretty hard to do. You need actual weights for anyone to have any sort of attempt at an answer other than purely guessing.

I would guess that 2sq will be plenty strong even at .125” but since you have no drawings I can only guess.

 

Just holding the tuff stuff RTT and two people, here is my rough drawing.

 

I would consider gussets in the corners or something tieing the legs at the bottom. There are all sorts of reports of bedsides spreading when racks and RTT’s are mounted to the top of the bed. I don’t have personal experience of this but it is worth reading up on.

 

Looks like what I did. I only have an 8 inch rise though

 

2x2x.125 6061 alum

 

If you're building your own, might as well add a 3rd crossbar.

 

I agree. I think the gussets are a good little extra security. I have the 8" rise tubes currently and have not noticed any bed flex.

Yes, this exactly what I am going for just taller. The main reason for going larger is to get my tent ladder to sit in the correct position and have the annex room for my tent setup properly, the sides would always be touching the ground and make it difficult to secure it to the ground. I am not that skilled with aluminum yet, but they sure do look nice. I think the .125 will work great I was really unsure between .125 and .187

I will keep this in mind if I run into issues with the route I am going.

 

Just be aware all tube sold is undersized in terms of material thickness. If the spec says .125 is to be between .112 to .125 it will always be closer to the .112. Coils are bought on actual weight and finished tubing is sold on theoretical weight.

 

I have no gussets and just the 2 bars. I have noticed no racking or flexing so far and I've done a couple 100mile runs on logging road.so far. I would think for the bedside to blow outwards there would have to be serious bending and flex in the bar itself to allow the width to expand. Anyway . Good kuck

 

I just finished my own rack for my first gen.
Picking up my RTT on Friday maybe.
I will take pics and show you soon.

 

With that set up you will not have any flex on the bed retails unless the tube flexes. Which I doubt that will happen.

 

Got them all welded up, seems they will do the job. They do have a little bit of flex in them as well which cant be any worse then the relentless fab bars I had on the truck before these ones. I did tig weld everything so I think they should hold up how they are, when I get them bolted down I plan on testing them to see if they will break