Custom roof basket access cab build

some quick pics i got of the mounts

finished up final welding on the brackets, ill put up some pics of those before I paint if anyone wants to see

going to hit it with another coat over the whole thing then upload some pictures of it being test fit again because it will be the same as when its actually bolted on just without the bolts

 

Rack looks good man

 

I like that you're using the factory mounting points for your rack. At some point I'll get around to doing something similar.

I do have some advice though. You're going to need some bracing on your supports. I'm afraid the supports will fold the first time you hit the brakes hard with a load up top. I would add a gusset in the "L" brackets you made. It would be preferrable if the bracket went past your weld point as well so that's not the weak link.

Keep up the good work, and congrats on doing it yourself.

 

Something like this.

 

OP, I know I probably should have read through this whole thread as others may have already mentioned this, but you cannot tap sheet metal, you would be better off with sheet metal screws, but I wouldn't recommend that either...

You should look into a Jack Nut, they are designed to use with sheet metal to give you a threaded hole. http://www.thread-rite.com/pop_nuts/jack_nut_installation.htm

I just did a quick search and found the link above. They might be available at your local hardware store, if not just order online.

 

OP, I like your rack. It looks good, but I have to agree with the above about the bracket. Since you will have a lot of force in the forward-backward direction, those brackets are definately your weakest link, especially with the holes in them. You only have about half-inch or less of steel where the holes are. I think it was a good idea to use those pre-fab brackets, but I really think they should be reinforced for this application.

Other than that, great job.

 

Right on Brad, looking good. The best part is you're doing this yourself and learning a lot about how stuff works...keep it up man!

 

thanks for the input, great idea!! definitly going to add these

i will have to weld them to the 'side' of the bracket facing closest to the roof because if i weld it on the flat surface where the bolt holes are chances are i wont be able to get a socket around them when i need to tighten

just srayed the whole thing with more bedliner spray, so im gonna have to wire brush it off the areas i need to do this welding

 

yea someone else mentioned that, but thanks for looking out!
ive been learning as i go on this so i quickly found out that getting barely a thread after tapping 22 guage sheetmetal would never work

i think these brackets are a good step over my original idea

 

could the guesset just me a triangle?would that be strong enough?
or does the 5 sides of the one you have drawn give more strength?

 

im not using factory mount points, the access cab doesnt have the factory welded threaded sleeves that double cabs like yours have

actually gonna have a buddies shop take the headliner off, drill the holes, get the bolts and nuts all set (with silicon on them before they get tightened) then headliner back on

 

A triangle should be fine, but I would extend it to the top so you can weld it all the way to the flat top pice that you added later (not shown on SMKYTXN's sketch). That way everything is tied together and you reinforce all the potential weak points.

 

im gonna go with this product so sick!

Westward 5NNR9 Rivet Nut, Knurled, Zinc steel, 1/4-20x0.590, Pk50

http://www.amazon.com/Westward-5NNR9-Rivet-Knurled-4-20x0-590/dp/B004ZROFG4

saves so much time drilling, would i still have to take the headliner off to catch a nut on the bolt or will it be fine to just tighten down the bolt from the roof side?

 

just be careful you can break the tool if you aren't careful practice a few times on some scrap sheet.

 

Will do

 

What if you just used a piece of flat steel against the truck for the mounting point and used a piece of square tubing to run from that to the roof rack to secure it. That way your would have a better bracket with higher strength. Let me see if I can draw something up right quick to show what I'm talking about.

Something like this.

 

Not understanding what your meaning man?

 

Say that the bottom piece you see in the pics with the two holes in it is a piece of flat 1" x 1/8" steel. The square tube could be welded onto it and angled to fit to the roof basket and be a stronger mount than the angle brackets you are using. For that matter you could even use round tubing instead of square to fit up to the basket from the cab. The flat piece would give you more surface contact with the cab and spread the load out better. The square or round tubing would be a more secure contact area than the thinner stuff you are using currently.

 

I'm gonna give the guesset a shot, but if I don't think it will hold up well I'll try out your idea. Thanks for the idea!

 

before and after shots of the gussets, still have to grind the lower weld flush (top part in this pic since i flipped the rack upside down to make welding easier) because that will be sitting on the roof