Roof Rack Design and Fabrication Weekend 5-6 Progress ;)

After what seems like a solid month of researching available roof racks and not finding what I really wanted I have committed to making my own. I've got a CAD and fabrication background and my day job is building one-off hotrods and rest-mods from the ground up so hopefully a glorified elevated rectangle is in my wheelhouse. I'll answer questions later but lets get to it:

Step 1: Why do I want this? What should it hold?

I keep the same basic things as any off-road enthusiast with the Rocky Mountains in their back yard on my truck. I also want the ability to take everything off of it quickly because I am not going to drive around the city with fuel cans, axes, shovels and other stuff I would never need during my nine minute commute to work. So the list of go/no-go is as follows:

1.) Rotopax Fuel Reserve. Just like you I do backflips if after I fill up I break the "302 miles to empty" in the DIC. I have coasted back to civilization after a weekend at 12,000 feet more than once so those are a GO.

2.) Axe, Shovel. The ground here is hard and I don't plan on digging out of any mud but the snow is at best unpredictable and just because it was pretty outside when you left for the day doesn't mean it will stay that way. They take up a small amount of Realestate up top and there isn't anything I can source on the trail side that I can chop up zombies with in a pinch so these are a GO.

3.) MaxTrax. I'm 50/50 on these. I've never used them in snow. I've honestly only ever gotten hung up twice out here and both times a little rocking back and forth nd some patience got out of the obstacle without even opening the door. However, I do see the use of them further South when we get into the sand so a removable bracket system for them is okay with me and I can also stack some more gear on top of them if need be so......who knows?

4.) Pelican 1720 (Rifle Case). Waterproof. Good amount of secure, lockable storage. All my recovery gear which is currently lodged in the drivers side rear storage compartment will live here and I am sure there will be room for plenty of other stuff. I actually considered one Ono either side of the rack but I own enough tool boxes to know that the more closable storage I have at my disposal the more crap I don't need that I will pack in there and never be able to find what I need. GO.

5.) HI Lift. I know.....it's an insult to the Jeep community to drive around with a jack attached to my truck but I had to borrow one on a trek last year to swap out a tire that got torn up on some jagged rocks so this thing is a GO. I did consider just making a bracket to attach to the bed cargo rails and keep it out of site but the overall plan of my rack is to keep the bed 100% free. I have the decked storage installed and that makes my bed a little over 7" deep (shallow) to begin with and it is a truck. So....input?

I can't figure out how to put descriptions under each picture so any questions or feedback I am all eyes/ears.

Lots of math to calculate the profile of the roof as well as the natural bow of the roof itself from the driver to passenger side. When mounted the bars rest exactly .1875" above the highest point of the roof supports. By my calculations...lowest profile roof rack in the history of ever. Super important feature. Loaded with all the gear it will clear my garage door by .625" (5/8") and the rubber weather gasket on the door should clean off the pelican case every time I back in.

So here is where I am so far:

 

Sub'd. Great start! I'll be following along. Can't wait to see the finished product!

 

Can’t wait to see the final product!!!

 

Sub'd. Looking good so far!

 

Here's my unsolicited input on each item

I would recommend a quality jerry can over a rotopax any day, especially since it sounds like you'll be constantly changing elevation. They're known to easily swell, and sometimes swell so much they puncture themselves on their own bracket. This is the can I have and it's well worth the price.

https://www.amazon.com/gp/product/B008Y4FSTM/ref=oh_aui_search_asin_title?ie=UTF8&psc=1

This video is pretty awesome.

https://www.youtube.com/watch?v=ydIw2cj0lrQ&t

The Krazy beaver shovel is what I would recommend here. They seem to get a lot of hate based on price (myself included) until I used one. I was winter wheeling and my front tire broke through the ice, and I was frame deep in mud. I was able to use a friends Krazy Beaver to dig through the thick ass ice with no issue to aid in recovery. After that I bought one for myself.

These seem to be one of those things that aren't needed in most situations, but when you can use them they help a lot. I watch a lot of australians off road on youtube and they use the shit out of these. Though if you're gonna get some, get 4.

Rifle case FTW.

Hi lifts are very handy, just make sure you have accompanying accessories to make them safe. I have this system and I'm very glad I do.

https://safejacks.com/collections/h...ucts/universal-hi-lift-stabilizer-for-60-jack

 

@EatSleepTacos I make it policy to take the advice of a guy that carries extra shaft parts. Love your setup. I did buy four of the MaxTrax. I was checking out the Crazy Beaver shovel over the weekend and I agree. A little pricey but seems like the shovel to have. My dad said the same thing about the Rotopax and I had already bought a couple of them. He was right, you are right. I've already replaced one that swelled pretty bad to the point that it didn't go back to its shape when I vented it. I'll check out the metal cans. Your input.....AAA+. Thank you.

 

Interesting

 

Love the spares.... noted for myself

 

Got some of the parts back from powder coat and started a little of the assembly......in the middle of putting the Maxtrax mounts on the bracket I had 2 of the 4 stainless lock nuts seize up on the posts. As disappointing as that was the following experience has made me a customer for life.

I documented the stuck fasteners and the prices of getting them apart which ruined the two pins. Took some pictures and emailed them to MaxTrax.

Now, with my experience in car audio and 12 volt vendors I fully expected to hear “tough shit”, “buy new ones” or “never heard that before” if I got any response at all.

Less than five minutes after I sent the email and the pictures I had a response from them, super professional. I provided the purchase receipt and without question they offered to ship out replacements.

That was yesterday afternoon and I got the shipping confirmation this afternoon. Less than 24 hours to remedy. Hats off to MaxTrax. Stellar customer service.

Here is the progress:

Rotopax Bracket. 2 gallon fuel. I made a second one just in case I wanted to run a second reserve. Identical to this one. The four open holes in the corners are for some rubber dampers I ordered off Amazon that haven’t arrived yet.

The sides without the covers and the two fuse holders for the dual Braille Battery system that’s taking the place of the spare tire under the rear of the truck. I’ll post up some pics of the battery bracket when it gets back from powder. It was a little more complicated because it also holds an oasis compressor with manifold and plumbing to put air outlets at the rear and the front of the truck to use for service. Hard lining the service lines front and rear so I can keep a shorter hose on board for air tools, tires, etc....

Other Rotopax bracket, axe and shovel bracket (took forum advice and ordered the crazy beaver-should arrive next Monday), and the Maxtrax bracket with the two pins that survived installed.

The powdered sides with the OEM matched side rails. I had the painted Quicksand parts clear-bra’d and they came back today. Not super impressed with how the company logos look under the clear bra so I’ll address that this weekend.

The “orange peel” is in the clear bra and they told me it would come out in the sun. I had the whole front of my truck done the day after I bought it and I don’t remember seeing this texture in it then but we will see what happens.

Test fitting some of the gear to make sure it fits before I start assembling the rest of the parts.

 

Looks great man. You should have powder coated the side rails quicksand instead of auto paint with clear bra. Prismatic makes a shade very close.
Can’t wait to see the final rack. Has an M-rack kinda vibe in the front.

 

You wouldn’t happen to know the name of their color would you?

It took four tries to match the back bumper caps, getting the paint from Toyota.

If you park three of these trucks beside each other (it’s happened more than once around here) all three trucks are a little different.

 

subd for updates. looks pretty badass so far!

 

Tundra Green.
Sounds crazy but it’s the closest I’ve found. Here’s the best pic I could find showing it next to the body color VS light bezels. It’s a shade darker, but you could away mess around with color mixing.

 

@mesojdm i checked out there website. Wow. I had no idea that place even existed. I’m going to call them tomorrow and kick some tires. The product seems affordable enough that if I order a few of their suggestions I wouldn’t be out too much if they didn’t work. Thanks so much for the information!

I knew the paint wouldn’t hold up on it’s own so clear bra was my only option because I thought there was no way on the powder coat but now it looks like it might exist. Awesome.

 

I don’t know how often you’ll be taking gear on/off, but the edges are what would concern me the most for chips & wear.(not the bra’d sides). But it’s Al anyway. I know Everytime I climb up I grab on the side rails. Just food for thought.

 

Have you seen that little clamp step that locks into the door latch? I saw a video of it on Instagram the other day. Looks pretty handy.

 

Sliders = permanent steps

 

HAHAHAHAHA. Yes!!!

 

@EatSleepTacos - extra parts, foam protected?! You sir both scare and make me feel funny at the same time!

@Relic_Micah Very nice! I’m always jealous of anyone with a CNC machine to play with!! You def have some fabrication skills my man!!

 

Saw this the other day. Same thing but no tooth guard. But way less cost.
https://www.amleo.com/seymour-sawtoothed-shovel/p/VP-SVXX/