Custom Aluminum Cap Rack

-Check out other custom things I build on my build thread.-

Needed to make a quick set of racks for the cap as we were going on a cross country ski trip and needed the extra storage of the rocket box on top.

Had some aluminum round and rectangular tubing sitting around from a previous build so went with that.

2”OD aluminum about .125 wall maybe a hair thicker, never measured. It’s strong as hell. I can stand on the center with no deflection. 2.5x1.25 rectangular aluminum tubing, maybe .125 wall.

Had to use the spool gun on the MIG welder because I didn’t have the correct tungsten for the TIG.

Used some cheap Amazon T bolts to attach to the cap rack tracks. I think I’m going to change the hardware soon as I don’t like the specific T bolts. (Snapped like 3 while installing) didn’t make me feel confident. May go with T nuts or some homemade T bolts.

Assessing the scrap. In the end I used about 50 bucks worth of metal for the build. In the future I plan to build a basket out of the 1” tubing.


Cut the vertical mounting pieces


Used a 2” hole saw to cut the notches for the tubing.



Drilled mounting holes for the cap track.


Welded em up.


Tool dipped the U bolts do attaching the rocket box and the outside rim of the tubing for a cleaner look. I have since installed black plastic pipe end caps.


Mocked up on the truck.


Rack and Box on the truck and ready to roll!


On the road outside Moab Utah, Castle Valley

 

Nice! Homemade AND made of leftovers, that gets you triple cool points.

It looks like you might have (or have access to) a CNC water or plasma cutter - have you thought about making speed holes and/or hardware cutouts in the tubing, say to run mounting bolts or a bungee/strap hook through?

 

Great work, looks awesome

 

Yeah I have a CNC plasma and router!
I definitely am scheming on speed mounts, probably going to build a basket or prinsu style t slot tracks.
This was just down and dirty quick to get the ski carrier on top for our trip. Now I can slow down and actually plan a little more.

 

Love seeing projects like this...Creating and building your own stuff.

Great job!