DIY aluminum roof rack build

So I'm planning to build a camper similar to the now classic ripcord one. But I want the top to go straight up and hang out over the roof a lot further. I'm also planning to use aluminum to offset the weight of the larger camper a bit. So I thought it would be a good idea to build a low profile rack for it to sit on. Here's what I've got so far.



Going to add more crossbars and a wind guard soon. Materials where only about $80. I didn't use any extrusions since I just need it to support the camper.

I started with just cutting the sides to length and tack welding the center mount.

Then I made some brackets for the front and back and welded them on.

Then I took measurements with both of them on for the crossbars.

I used straps to hold it together while I tacked everything. It took a few frustrating tries before I thought to do that...
Excuse the messy workshop.



This is where it's at now. I'll be adding more crossbars, the wind guard, and a coat of paint soon. I'm also planning to mount a sim light bar in a cutout in the wind guard.

 

I remember there's a whole thread on DIY racks like this with some cool ideas, wish i could remember what it's called. If i find it ill link it in here for you
edit: here it is. Some seriously cool racks in here!
https://www.tacomaworld.com/threads/diy-prinsu-style-shell-rack.521186/

 

Thanks! Mine is almost done. I'll make another post soon here.

 

The frame of the rack is done. Just have to make the fairing to cut down the noise. also probably putting some rubber under the mounts to raise it up a tad and dampen vibration. It was unbearably loud above 45 until I wrapped parachord around the first bar. I'm honestly shocked at how much that helped. Still a bit noisy at 60 and above. So will definitely be doing more.

 

Aeolian noise on square bar can be amazingly loud. When I made my platform rack, before I got the platform on the frame it wasn't comfortable to drive over about 40mph. Putting the flat boards up top silenced it the droning, oscillating wind noise leaving a little white noise.

Looking at your rack I doubt the middle ones are making much as close as they are to your roof, the back ones may be generating quite a bit of noise as well.

 

I made an air dam for it and it's pretty much silent now. I'm getting it painted right now. So I'll post pics soon. Pretty happy with the looks and performance so far.

 

Do you plan to attach the overhang of the camper to the rack?

 

Ya, that's why I made it so low profile. I made the air dam go about two inches above the rack to help a bit with the campers aerodynamics too. I may make a bigger one if it ends up being loud.

 

Finished the air dam and got new shoes. Turned out quite nice.

Before sharp edge cleanup and paint


After paint

 

I like it. Good job. How much do you plan to load onto it? And how confident are you?

 

Mostly just built into hold the weight of two people sleeping on the overhang of the camper I'm building. I think a rooftop tent or something would also be fine. the whole thing feels rock solid and it's completely welded construction other than the wind deflector. I'll probably throw kayaks and stuff up there when I don't have the camper on. As for the weight rating, maybe 500 lbs if I was driving like a grandma. I would be more worried about the weight up so high than the integrity of the rack.