DIY Roof Rack

I've had my 2017 Taco since the new year and have been looking for a sturdy roof rack that I can put my 14' canoe on and didn't cost more than a monthly payment. I found the Princu design rack and thought that was great until the price (greater than a monthly payment). I dug through many of the posts here for roof racks and got pointed to extruded aluminum t-slot. I eventually settled on 80/20 material, a quick design and about 6 hour of work put together reasonable attempt (IMO). I am down to trim out and have just a few parts to swap out and a list of thing to do different next time.

Once I get it all finished out I will post a parts list, right now I'm looking at coming in just under $300. Wind noise also was only noticeable 65+ with a good cross wind. I plan on getting some fill strip to cut down on that.

The first thing I would change, and may do within the year, would be to have longer side rail by about 12-18". This would let me set a cross rail behind the shark fin, the top of the rack is just above the top of that.

I have a plan for a modular bed rack to go over my tonneau cover. I will post that when (read if (riddled with ADHD)) I get to it.

 

How did it go?

 

Fill strips helped a little with the wind. Gonna be a project of little tweaks.

 

I'm think of making one with the t-slot just trying to figure out how I want to do side pieces so far I'm at under $200 w/o the side pieces. So how did you make out with your design.

 

Overall the design is ok. It get the job done and looks clean IMO. I have added a few extra cross pieces for looks and the ability to attach different lengths of things. It really shines when hailing a canoe on top. Solid tie downs etc.
If I where to change any one thing it would be the front cross piece from the triangle profile to a square profile and angle that so attaching a wind fairing would be simpler. (Kinda like the way a Princu attached). The sides are clean with the triangle profile but where tricky to line up and space just right.

 

Ya I was thinking of side rails like the pinsu with front deflector. I also was think of different t-slot for the main side rail and doing shorter flat stock for front to follow the body line of roof.

 

In the end I picked this material for the ease of building and really came out ahead.