ERMB's D-I-Y Rack System Build

I ran into this same issue, with the 3in bolts, I used some nylon(plastic) spacer washers I found at a local hardware store that had some thickness to it, I believe it was 1/4"thick.

 

I'm lurking on this thread as I am looking to do something like this mounted to my allpro pack rack.

Don't be afraid to order the exact bolt you need, once you know what it is. It will save you considerable headache trying to make something work that is not intended to.

https://www.fastenal.com/products/f...00 Fasteners"|~ ~|categoryl2:"600001 Bolts"|~

 

Thanks man. But I should be good. Went with a longer bracket, not spacer. So it should all fit fine. Cutting the frame of the rack now. Will update in a little.

 

Okay so here's my update. Had to junk a lot of hardware I bought cause I couldn't get enough height. Waste of money
But I went with 3" spacers (galvanized pipe cut). And I cleared the roof. It has a slight forward lean to it. But I can live. What do you think about the space between the roof? Only about an inch.
I just need to find long enough bolts to go through the spacers.

(Pictures of progress so far. I know it's not all clean yet. I'm just getting measurements and test fitting)

 

I think the inch gap is more than adequate. could even tuck it in more if you wanted.

 

I'll keep it where it's at. And I'll probably put a rubber pad under the cross bar just invade of flex

 

That's about the same gap I have at that point on my rack too. I think your good to go as well. Looks great man can't wait to see it all done. Some fine on the fly engineering going on in here lately!

 

You could cut a section of pipe to make a custome spacer?

 

That's what I did

 

So I have everything made and test fitted. All good
I'll be busy this weekend. But I will post up pictures of completed project when I get it all painted and done.
I used a 3" pipe as a spacer. Used two "L" brackets to make a "U" on each spacer. And it slides right into place.
Thanks @ERMB fir your original post. Saved me lots of money

 

Sorry, missed that part

 

Geez.... This thread has blown up - it's cool to see all these rack ideas. I was in the same boat as some of you on the welding thing not too long ago. If you want to learn, don't be intimidated by it like I was - just do it. Get a 110 welder and spend half an hour on YouTube. It really is that easy. The best tip I can give you is to start with 7014 rods. They are a little more concave and I have found them to be much easier to weld with. And get an auto-dimming helmet (or two if you have kids- mine love to watch). If you are doing a cab rack, plan on a fairing. I thought there was a helicopter above me when I drove mine without it.

 

Great info! X2 on the fairing, I had a similar problem but I was able to fix it by going a different route. Because of all the holes the wind travels through them and creates a terrible racket up there. On the first crossmember I countersunk some holes in a piece of plexiglass. It served two purposes,1st it took away the nice whistling through the holes. 2nd it made a nice surface for the lumber I haul to slide across and not rub off the nice paint job I gave it every time I haul something. As well as it works I think a fairing would be better to push the airstream above the rest of the rack as well making it even quieter.

 

Good info. Yeah I totally plan to run a fairing. I'm going to get a sheet of aluminum and cut it, dress up the sides, and do a fairing. Gonna take me a long time though, not the steadiest with a dremel. Lol.

 

Could you possibly take a close up of your fairing? Underneath, how it's mounted, what you rigged up?
Thanks boss

 

@ERMB
You just did 2 coats primer, 2 coats black, 2 coats clear?
Did you just paint it once it was all assembled

 

Sorry for the delay! I had parents night last night at school, I got home and fell asleep on the couch.

After the 2 coats of Primer I used Rustolium Bed liner for some texture and then topped it off with some gloss black as my topcoat for easier cleaning. I ended up spraying some parts separately(decorative side rails) then added them on after. My original intent was to spray each piece as I went but the eagerness of getting it all completed and on the truck got the best of me so for the most part I sprayed it while it was put together.

 

hahaha thats exactly how i am, and i was hoping you were going to say you painted it together
thats what I'm going to do, paint it all, and paint the side look good parts separately.

 

Here's what I did. This was intended to be a prototype, I just haven't gotten around to building the real deal. I need to alter the shape of it and cut it out of some thick ABS or aluminum.

 

What did you use for the fairing?