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Custom roof basket access cab build

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Bradpad, Apr 18, 2012.

  1. Apr 25, 2012 at 6:17 AM
    #101
    Ross Dence

    Ross Dence New Member

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    Attached are a few pics of a basket I built to go over the bed cover on my 2009 4cyl 4x4. My welding skills aren't the greatest but I wanted some additional storage space for when I go camping and I didn't want to have to remove the truck bed cover to gain additional storage space (cover keeps items dry during rain, which always seems to happen when I camp).

    I was originally going to go with a roof design but went with this instead as it was easier for me.

    2012-04-25_07-39-20_282.jpg
    2012-04-25_07-39-30_641.jpg
     
  2. Apr 25, 2012 at 10:35 AM
    #102
    Bradpad

    Bradpad [OP] Well-Known Member

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    absolutely man, but once I get the proper size lights and tabs then ill wire brush the paint off and get those welded on over the next couple weeks
    going to have 6 lights, two per each of the three 'sections' on the windshield facing side of the rack

    on the bed-facing side im going to mount a hi-lift jack
    then somewhere on it ill mount a fire extinguisher
     
  3. Apr 28, 2012 at 7:26 PM
    #103
    Bradpad

    Bradpad [OP] Well-Known Member

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    been a couple days since the last update computers been acting up, but made good progress on the rack,
    pic 1 - prepaint

    pic 2 3 pained (one can of spray on bedliner just the top not bottom still have to weld on the brackets to undernearth when holes are drilled so i can line up where they need to be welded to)

    pic 4 - close up

    pic 5 - brackets that kick out 2 inches from the recessed rain drip part of the roof because the rack is a couple inches to large (width is a bit to big at 48" front and back)
    bracket is a 5/8 wide by 2.5" horizontal and 2.5" horizontal bent steel, welded 1/8 thick steel plate cut 1" tall and 2" wide

    THOUGHTS?

    2012-04-24_23-34-50_409.jpg
    2012-04-25_20-55-39_399.jpg
    2012-04-25_20-56-00_166.jpg
    2012-04-25_20-56-16_141.jpg
    2012-04-26_23-01-59_778.jpg
     
  4. Apr 28, 2012 at 7:29 PM
    #104
    Bradpad

    Bradpad [OP] Well-Known Member

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    in this pic you can see the paint I'm using

    also picked up a mini fire extinguisher that has a plastic mount that I can screw into one of the outer tubes on the rack to mount that way

    2012-04-26_18-52-09_936.jpg
     
  5. Apr 28, 2012 at 7:47 PM
    #105
    colinb17

    colinb17 If at first you don't succeed, don't try skydiving

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    I use that bedliner for everything. works great.

    be careful with those brackets, once you mount them up, i'd push the rack forward and back to see if you get any flex. that bend is not going to have a ton of strength to it. maybe think about runing a bead on the inside of the bend in the bracket to increase the crossectional area at the bend?
     
  6. Apr 28, 2012 at 7:52 PM
    #106
    Bradpad

    Bradpad [OP] Well-Known Member

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    I could try that on an extra bracket I have to see if there is a strength increase,
    I actually lucked out and Lowes somehow had the width and length bracket I wanted to build, so they are pretty sturdy as they sit I didnt "ghetto bend/cheat"to get them like that myself

    made by stanely and zinc plated but i grinded off the zinc coating where i needed to weld
     
  7. Apr 28, 2012 at 7:56 PM
    #107
    Bradpad

    Bradpad [OP] Well-Known Member

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    K&N polished intake QTP electronic exhaust cutout
  8. Apr 28, 2012 at 8:03 PM
    #108
    colinb17

    colinb17 If at first you don't succeed, don't try skydiving

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    yeah, those are handly little pieces, and they are pretty strong, you're just putting a good amount of leverage on them. won't know until you try i gues.
     
  9. Apr 28, 2012 at 8:42 PM
    #109
    Bradpad

    Bradpad [OP] Well-Known Member

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    Ya I get what you mean now, definitly running a bead along that bend to make it stronger Ike you said
     
  10. Apr 30, 2012 at 4:53 PM
    #110
    Bengland25

    Bengland25 Never Forget! 343

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    Brad, Looking good man, Cannot wait to see the finished product mounted up!

    You have all the bolting on and securing the rack all figured out??
     
  11. Apr 30, 2012 at 5:40 PM
    #111
    Bradpad

    Bradpad [OP] Well-Known Member

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    Thanks man!
    And yea, going to set the mounts were I want, Mark the center of each hole with a sharpie, and dril those points big enough to fit the threaded part of the 1/4 bolt from
    headliner has to come off to get a nut on from the underside

    might also just cut a 3" x 1" eighth inch steel piece and drill holes in it to place on the interior side so the nut doesn't compress against the roofs metal too much and distributes the pressure
     
  12. Apr 30, 2012 at 5:48 PM
    #112
    Bengland25

    Bengland25 Never Forget! 343

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    Yeah I was thinking you should use some type of backing to protect against compression and stretching/tearing the roof. How you planning on water proofing after drilling holes?
     
  13. Apr 30, 2012 at 5:51 PM
    #113
    Bradpad

    Bradpad [OP] Well-Known Member

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    Gonna touch up paint the holes after they are drilled

    and silicone on the upper part of the bolt, on the metal around the holt itself , and on the top and inside the nut so there is a silicone barrier for any water that wants to seep in
     
  14. Apr 30, 2012 at 5:55 PM
    #114
    Bengland25

    Bengland25 Never Forget! 343

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    Sounds good man! cant wait to see it done, Should be pretty good looking!
     
  15. May 1, 2012 at 8:19 PM
    #115
    Bradpad

    Bradpad [OP] Well-Known Member

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    ran a bead right at the bend in the bracket, increase strength

    pics 1 2 3 are of the bead

    pic 4 - painted up, lower part still masked off (bedliner spray on bottom of bracket would scratch)

    2012-05-01_20-50-01_692.jpg
    2012-05-01_20-50-06_492.jpg
    2012-05-01_20-50-15_998.jpg
    2012-05-01_23-00-34_810.jpg
     
  16. May 3, 2012 at 8:35 PM
    #116
    Bradpad

    Bradpad [OP] Well-Known Member

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    was thinking, and im going to make the base more of a lattice structure to make it more of a floor and make it was easier to balance things on, right now i have thr 4 tubes going front to back so im going to add two side to side
    (cut into 8.5" pieces to be weld onto the existing tube supports i already have)
     
  17. May 5, 2012 at 8:32 PM
    #117
    Bradpad

    Bradpad [OP] Well-Known Member

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    added tubing 'side to side' to interlink the 'front to back' tubes i already had

    not welded yet or perfectly lined up but you get the idea

    2012-05-04_21-48-04_44.jpg
    2012-05-04_21-48-11_497.jpg
     
  18. May 8, 2012 at 8:17 PM
    #118
    Bradpad

    Bradpad [OP] Well-Known Member

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    make the brackets more 'beefy'

    welded a 1" wide by 3" long piece of 1/8 steel to what was previously the area I thought I would weld the roof rack onto, but having the rack sit on a a weld 1/8 inches long (width of metal) and .5 inches wide (width of square tube) did not give me peace of mind :p

    so now there is the flat piece of steel that the rack can sit on at all four corners of the roof, and will be able to run nice thick beads along the 4 sides where the square tube contacts the flat metal top piece of the rack

    4th pick is my crude way to kinda show how it is gonna look when welded, the general idea

    2012-05-08_21-51-36_67.jpg
    2012-05-08_21-51-54_697.jpg
    2012-05-08_22-35-25_598.jpg
    2012-05-08_21-55-47_50.jpg
     
  19. May 8, 2012 at 8:21 PM
    #119
    Bradpad

    Bradpad [OP] Well-Known Member

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    all of it (besides bottom for welding) is painted up with a couple coats of bedliner

    2012-05-06_21-05-12_205.jpg
    2012-05-06_21-05-18_890.jpg
     
  20. May 10, 2012 at 3:01 PM
    #120
    Bradpad

    Bradpad [OP] Well-Known Member

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    got the mounts welded on and at proper point to fit in the recessed area where the roof moulding goes
    this was at night, and raining so thats why my taco is in the garage for this test fit (nothing bolted in yet)
    still have to give the whole thing a couple more coats of paint but
    hows its lookin?

    2012-05-09_22-27-51_960.jpg
    2012-05-09_22-28-20_689.jpg
    2012-05-09_22-29-35_29.jpg
    2012-05-09_22-29-55_168.jpg
     

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