DIY prinsu style shell rack

So I ordered the material for the side plates and some lights that I will be adding to mine today. Hoping to get some time this weekend to start laying things out and then order the cross bars next week. I do have one item I'm looking for some clarification on though.
I'm planning on using 1 1/2" square tube for the mounts and I'm a little uncertain how others are attaching them to the rails on the cap. I see that people are using carriage bolts, but are they just grinding the head down enough to fit in the rail? Or am I missing something else? Mine came with the Thule rails installed from the factory if that makes a difference.

 

Cut mine out just now and they came our surprisingly good on the plasma table. If anyone needs help cutting out their design let me know. I might be able to help.

 

Wow! That looks really good! I don't really have my own design, but what would you charge to cut similar once? Planning on swapping my RTT setup with Camper shell next week, so will need one

 

Its more secure to get fitted rectangular slot nuts than either carriage bolts or the drop-in and twist to lock nuts that come with Thule bases. Both of those have limited area under the track lip which is only 1/16" thick. I've had the twist-ins pop loose and the limited area can deform the track lip or even rip through under load.

Measure the width of both the opening and slot as well as the thickness and depth of the slot in the tracks since not all slot nuts will fit or have best grab.

Edit-something like these https://www.amazon.com/s?k=slot+nut...refix=Slot+,automotive,587&ref=nb_sb_ss_i_2_5

I made my own from some 1/4" aluminum that I milled, drilled, and tapped for the 6mm x 1.0 Thule bolts.

 

It depends on a few things..... are you providing a design, are you providing material, where you're located??

Shoot me a PM when you're thinking you'll need one. I can also help with the designs if needed.

 

sounds good man, thanks! I will PM you once I get the shell. Cheers

 

These are all great! Makes me want to entertain myself with an attempt... lol

 

Will be picking up my side plate material tomorrow evening!

 

Morning everyone.
Does anybody have a list of hardware required? (bolts, nuts, washers etc..)
Thank you

 

So I am not a Taco owner. I did get inspired from this board and I thought it appropriate to post. You guys really take the Mods to a different level, and I can dig that!. Here is a link to the build in progress. However, I wanted to specifically point out the rack that I built based on the ideas picked up in your thread. Thanks for the inspiration fellas

https://www.expeditionportal.com/forum/threads/project-2013-ram-2500-mods.208411/

Made a cap rack for my ARE. I came across some 2020 series (2”x2”) extrusion at the local metal shop. These were made into a 9’x4’ frame of some Sort with various crossmembers. Picked up exerything I needed for the rack for less than $180. I disassembled it. The stuff is really fun to work with and it’s like an erector set for adults. I’ve decided to go with a 3/16 x 3 alubar for the sides. I am certainly no metal expert but I think this turned out pretty good for 75% less money than a prinsu. I can always add holes later if I want to and the sides and the 2” x 2” crossbars are ridiculously solid.

I started with the unfinished aluminum look. I just like the black better. Also, am absolutely IN LOVE with Raptor Liner, so.. it had to happen.

A few key differences are that I do not have any holes in the side rails. I just felt like it may cut down on the whistling while traveling at highway speeds. I also wanted a REALLY low profile. I am roughly 3/8 in off the center and about 5/8 on the ends. I like the way this turned out for sure. The 2x2, seemed like overkill, but I wouldn't change it. I can still get u-bolts under if I need to for my cargo box. Overall they really are not that much heavier that the 1x2 cross members, its just a bigger hole in the middle of the bars.

 

Just finished my camper rack. Plasma cut the side plates and painted them with bed liner.
Mounted the whole thing with smittybuilt mounts. Planning on designing awning brackets and a Cab Rack next.

 

Finally got mine installed yesterday. Went with 1 1/2" square tubing for mounts and used some tslot nuts from Tnutz.com that I cut to fit and some bolts with the heads cut down to fit into the Thule rails on my cap. If I had it to do over again, I would have just used some short bolts from the top of the mounts as the amount of head left on them is only going to add very minimal strength.

 

Clean work, brother.

 

I'm sure some of you guys saw the camper rack I did a few posts back. Just made some progress on a matching cab rack.
Let me know what you guys think!

 

First mock up of the Cab Rack. Still working out the front and rear bracket size.

 

Brackets made and everything fully mounted. Just need more bars and to paint it now.

 

Has anyone done this and mounted directly to the caps track system without using mounting feet? Is this even possible? I have the proline tracks going on Friday night and have ordered 7 of 1x2x47 pieces for my short bed. I’m just deciding if it will fit traight onto my track with the track nuts or if I’ll need to go build the mounting feet out of the tube like others have. I want mine as low profile as possible full clearing garage entrances.

 

Interested in an answer as I have the proline tracks waiting to be installed on my topper.

 

I saw where someone used a hat bracket to attach to their rails. I’m curious if anyone has tried anything like this? I have the track nuts and would just need to find the correct bolts to fit in the 80/20 this would be for a cap version. But at the price of the ones locally if these would work I could easily put 3-4 on each side. I checked at a local hardware store and they have them for 3.99 a piece.

$36 Genuine Unistrut Brand P1047-EG 5 Hole "U" Shaped Connector Bracket for All 1-5/8" Strut Channel

Unistrut Brand P1047-EG 5 Hole "U" Shaped Connector Bracket for All 1-5/8" Strut Channel

 

Got the side plates 1/4x3x60 from metal supply here in Knoxville for 34.76 otd today. Basically just got a 10’ piece and they cut it in half for me. I’m going to cut it down to 56” and round the ends off. Total cost for everything less than 210.00 otd. Ordered the extrusions two days ago and showing delivery Monday via UPS. Picked up a box of 50 1/4x20x1 from fastenal for 11.00. I’ll make another post with complete break down of a dcsb rack parts and cost for anyone else wanting a cheat sheet since in 49 pages I haven’t seen a whole break down.