ERMB's D-I-Y Rack System Build

Those rivnuts look pretty interesting.The last time I was at our local junk yard to by the rails and rack I have now I grabbed a couple of the factory inserts from some sort of minivan I took the rack from but I don't even know what these are called,they are rubber with a nut inside

 

I google plus nuts an just found metal ones,any idea where to find rubber ones,I pretty sure these were factory installed..

 

may have found them ??http://www.ebay.com/itm/M3-M4-M5-M6...THREADED-BRASS-INSERT-RIVET-NUT-/201499994097

 

Here's my take on this. I already had a VanTech J1000 rack on my canopy, so used that as my base. The sides of the crossbars each have two threaded holes in them,

The sides are 1/8x1.5" flat steel, the round cross bars are 1" conduit. To attach them to the side rails, I used plumbing end caps that fit inside the conduit. Then everything got painted with Rustoleum spray-on bedliner and assembled with stainless hardware.

When I was building this, the steel sides seemed pretty strong and a good size. However, once I mounted it on the truck, it seems a bit "dainty" now, and not quite as solid as I was hoping it would be (if I grab the sides and try to shake it, I can get more flex out of it than I'd prefer). So, I'm going to have to re-do that part sometime soon (probably with angle iron instead of flat), though it is plenty strong for what I will be putting up there (kayaks and some recovery tools).

 

Add slim one row cheap LED light bar to rack. One pic off. One pic on.

 

I'm wanting to add one to mine as well. How did you run your wiring?

 

Their a little channel running down side of windshield. That the wires fit perfect.

 

I was wanting to put on my 20 YO Confer rack w/ no factory rails and stumbled on this thread.
3 hours and 29 pages later....Solid work dudes!
Great read!

 

Im really wanting to make a roof rack like this, but I already have OME rails attached... Has anyone attached one to OME rails? If so, how? U-Bolts?

 

Started working on mine today. Hope to have it painted and mounted this week

 

Looking great so far! How much room do you have at the center point of the crossmembers, looks rather close on some the middle ones. I used some vinyl washers to raise my front section to match level with the back, it may give you some more clearance if you need it.

 

They are spaced 1 ft on center for the back 5 ft of the 4Runner

 

Sorry, I was referring to height under the bars to your roof.

 

Ah okay. On the pictures posted, there's no brackets to go into the factory so yes, rather close to the roof. I'm adding the brackets as we speak so it'll sit a little higher and I'm using these guys for support in the front

https://www.mcmaster.com/#standard-vibration-control-levelers/=16l40aq

 

Ahhh, perfect good call!

 

Does anybody have detailed pictures of how you made the rack towers, the mounting to the factory threaded inserts, how the rubber gutter insert seals around the towers and the mounting to the rack? I want to make sure I build the towers and the connections solid enough for a RTT or other heavier items

or point me to the post number on here, I didn't see anything really detailed for that while browsing through

 

Finished up the rack and mounted my awning to it. Looks good and feels very sturdy. Excited to load it up in the next few weekends

 

Looks awesome Matt! How was the hookup for the awning, did it go smoothly, seems like there wold be plenty of options out there for hangers.

 

Very easy. I used some of These off the rack and into the awning. Bolted up very nicely