ERMB's D-I-Y Rack System Build

I just used L shaped brackets

 

Drawing something. The idea is to have two independent rails, just like OEM, and detachable cross bars to avoid wind noise when not in use.



This is a 2” , 1/4” aluminum angle for rails.

 

Such an awesome diy project, I can’t wait to give it a go! If you don’t mind me asking for those of you who did the full cab rack, what was the length of your side pieces?

 

Gave my go at this project and I love the way it looks. I will eventually do the side panels to cover up my not so pretty mounts. My cap (mid height A.R.E) doesn’t have a flat spot anywhere on it so I had to improvise. It is still sturdy as hell and will love the space up top for skis etc and allow space for the dogs in the back.

Thanks for the write up.
Total cost for me with paint was ~$175

 

I don't remember the length off the top of my head but if you check out my.first few posts I'm sure I put it in there somewhere. Good luck with the project, if for some reason my measurement isn't in there let me.know and I'll measure it for you tomorrow and post it.

 

@ERMB, What gauge Unistrut did you use? I noticed you used the lower profile 13/16” height...any complaints?

Input from anyone else would be great too.

I’m hinking about using the 14 gauge 13/16” for cab tracks as they may mold to the contour of the roof while also reducing the limitations of the factory weldnuts. then perhaps 12 gauge 1 5/8” or 13/16” for the rack itself.

Has anyone else made cab tracks with the unistrut? I’ve seen it used for toppers so dont see why it couldn’t be used for the cab too?

 

I doubt you would get the unistrut to bend before the roof does. The only way you’d be able to do that is if you put them through a slip roller first.

 

Do you remember what the width of your rack was?

 

Anybody using black hardware similar to what prinsu uses?

 

I believe I found everything to run black hardware in a similar design to prinsu but with ERMB specs for struts.
https://www.mcmaster.com/#97763a348/=1bnk79i
https://www.walmart.com/ip/1-4-Lock...8589&wl11=online&wl12=274798469&wl13=&veh=sem
https://www.mcmaster.com/#90618A129
https://www.mcmaster.com/#94407A104
https://www.mcmaster.com/#98026a111/=1bnkf2v

 

looks good man nice job.

 

Im still debating making the cab rack and still sourcing the spacers, bolts, etc but i was just gonna use the thicker strut for feet at the mounting holes and the thinner strut as the actual rack but run short of windshield and fab a fairing or get one from a company and attach it with angled brackets.

 

As someone mentioned the unistrut definitely wont work as a cab track system, its much to stiff, even the 14 gauge 13/16”. My next idea was using the track system from the bed. They are more “plyable” than the unistrut, have a factory look to them and the short bed length track are almost an exact perfect match for double cab mounting holes. The challenge will be making the tracks level rather than canting outwards like the roof line. Leveling would be easy enough if leveled only at the mounting holes but this sort of defeats the purpose of spreading the load across the roof rather than just at the mounting points.

The primary reason I’m determined to build a solid track is for the easy install and removal of the rack itself. Not sure why I want to take it off but I don’t like the idea of having it semi-permanently attached.

Not having seen them in person the rhino-tracks seem over priced and under built for strength. Anyone have experience with them?

 

what size spacers did you use?

 

Honestly i dont think anything will be pliable enough and strong enough at the same time to run as a track system and contour the cab. Thats why most guys and major rack companies run the spacer and/or bracket combo.

that bed rail idea could be interesting though.

 

2" front, 1.75" rear

 

awesome thanks.

 

Thinking about leaving the cantilever over the cab and just attaching some rubber bumps tops incase it flexes a lot. Also not to sure how I'm going to mount it to the camper cap. I picked up some more L brackets I may just put one in each corner of the cap

 

How did you attach this to roof? Yeah using the thicker stuff in middle is tough cus it isn’t flat across. I used bigger pieces outside and thinner across.

 

It's not mounted yet, waiting for another nice day. I'll be drilling through cap and using some pieces of strut to build it up.

What has everyone been using for paint? Looking for something that is durable