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

So like @bagleboy stated.....you don't have threaded inserts in your track area but they can be added. Threaded inserts aren't hard to come by it will just require some alignment, marking and a special tool (although I've seen it done with just a nut and bolt) to set the threaded insert. I really need an access cab to make some measurements for and to address things like this. Everything out here is a DC.

 

My personal way of thinking is that they eat a lot of real estate and with our lack of rain here most of the year aside from snow I have no use for them in the summer. Easier for me to pull 4 m6 fasteners and remove the bracket than to fight with the four individual pins to get them off. They are a pain in the ass to line up on their own and if you've messed with them very much you'll know about the stainless threads/stainless loc nuts and how tough they are to break loose without binding up on the threads.

 

I just realized that the rack doesn't go past the fin. Would there be any possibility to make one a tad bit longer to pass that?

 

This one was the first one. The production ones have the seventh bar that is spaced behind the antenna. Makes them 11" longer than the one I have on mine.

 

Random guy in Texas dances with glee.
@Relic_Micah, any chance you can post the height of last bar and distance behind fin?

 

Threaded inserts, jack nuts, rivnuts, several different names for similar items. Right off the bat I can think it would be possible to make a template to standardize placement of these. Any of these fasteners require a larger diameter hole than a simple nut/bolt/washer and I can't overstress the need for extreme care when drilling the channel above the clamshell doors because of air bag curtain proximity. Over the front doors the risk is minimal. Having dropped the headliner and seen the difference between the proximity of air bag hardware in a DC vs an AC I would recommend dropping the headliner, removing 3 bolts across the top and loosening 2 more down the rear pillar that hold up the air curtain to be able to move each air curtain safely out of the way before drilling the channels on an Access Cab. Not having preplaced nuts is a pain but the risk drilling the access cab roof blind is much greater than a DC and not worth it. You can see from this pic how the airbags are literally tucked right under the channel over the clam shell doors.

 

Is it a fair guess that you’ve ‘reversed’ the mounting strut for the last support? In this pic it looks like the vertical riser is forward in the design. With the added length, would it be better with the vertical riser towards the rear?

 

We just left the shop for the day but I will get a measurement for you tomorrow.

 

That is correct. It was as simple as making the left bracket the right bracket, etc... That flipped the mount point reverse by 4.65".

 

Well aren’t you the smart one.

Pretty obvious solution now that I think about it. I’m guessing that any variance in width at this point is pretty negligible.

 

PS,

I’m in for one. I recall there being comments about using the center hole mounts in a ‘beefier’ design. Will the first run, or future second run, have the holes in the side rails to accommodate buying the center mounts in the future?

 

Yes sir. The bars being set at 48" and the placement really shores the rack up when you put it together. The test model (one in this thread) had the side armor integrated and the production product actually allows the side armor to be removed without taking the rack apart.

 

Yes I addressed that in the final design. In the one you see in this thread the side armor was integrated in the assembly of the rack. The final production ready CAD files have them removable with the rack still on the truck to allow wiring, etc.... so the holes for the center mount brace/tab have been added and the rear most mount points have been doubled and relocated a little further back to account for the flipping of the brackets for the xL version of the rack.

It's coming to market with the one in the picture (design changed to seven bars and a little more length),an xL version that extended all the way to the rear of the cab (11.0" longer overall, 8 load bars), and a few other cool things. The xL requires relocating the OEM antenna and I think when you guys see how we are doing this.....you'll like it.

The revisions have been plentiful and I really owe a lot to the feedback and questions from TW. Aside from our instagram (@uptopoverland) this is the only place the rack has been released. We have a place holder web page up right now (www.uptopoverland.com) but incase it gets crazy and you decide to order.....do not order before you check here. When the items are added to the website I will post a discount code for forum members. Make sure you get that from here before you order anything.

 

Hey Everybody,

I spent a lot of time in the shop today with @Relic_Micah, he's an awesome dude with an awesome product. It's not my place to spill the beans but I'll tell you all right now that you better get psyched!!!

Sincerely,
Future owner of a badass roof rack...

 

Already super psyched!!! Now even more psyched.

 

I don’t think it’s possible to prepare yourself....

 

That sounds amazing

 

@Relic_Micah any updates to keep us on the edges of our seats this week???

 

I've been working with him the last two days, he's cutting a lot of parts right now and has some nifty tricks up his sleeves. We will probably have some stuff to show you this weekend!

 

Crowdsourcing!