Custom Roof Rack 3rd Gen DCSB

I have been thinking about roof racks alot recently and I haven't found exactly what I want and I have not found anything close to the price I want to pay. So now I have decided to build. Here is the parts list I have so far. I like the profile and some of the features on the prinsu(especially the mounting method), but I also like to functionality and the look of the GOBI racks. So let me know what you guys think.

• 1" tubing 11 gauge(whatever I have laying around ~20') - for the bottom rails that follow the contours of the roofline and for connectors that connect the bottom rails to the top loop.
• 1" tubing 0.095 wall(not dom, I think the metal guy told me electrically welded, but I thought DOM was electrically welded too)(40') - for the top loop and the connectors bars on the top plane of the rack.
• 1" long aluminum spacers 1/4" hole, 5/8" OD - for the tabs on the lower bars to mount to the factory threaded holes.(x10) (hole size will be dependent on the bolt size)
• 1.75" 1/4 - 20 bolts (x10) - to bolt the rack to the roof(Are these correct?)
• ~1/8 aluminum plate to bolt to the front for a fairing
• 3/16 plate- various tabs on the rack
• 3/8" thin wall tubing - for the connectors from the center tube to the bottom rails to make it more like a roof basket.
• Bolts and nuts for front fairing
• 30in slim light bar. - I found one on superbrightleds.com (does anyone have any experience with that one? Its $80 but its only 1..170" tall)

Specific questions I have are listed below:

• Are the spacers the right OD? Will 5/8" be wide enough to make the roof rack stable?
• Bolt length and thread stated above.
• Light bar question stated above.
• How are my metal tubing choices? Does anyone have better suggestions?

 

Subbed

 

sub

 

So here are the changes I made to my original plans.

• 1" tubing 0.95 wall(whatever I have laying around ~20') - for the bottom rails that follow the contours of the roofline and for connectors that connect the bottom rails to the top loop (Free)
• 1" tubing 0.095 wall(not dom, I think the metal guy told me electrically welded, but I thought DOM was electrically welded too)(40') - for the top loop and the connectors bars on the top plane of the rack. ($53)
• 1" long aluminum spacers 1/4" hole, 5/8" OD - for the tabs on the lower bars to mount to the factory threaded holes.(x10) (bolt is 6mm, but 1/4" spacer hole is closest)($26)
• 40mm long
  $9 M6-1.0 M6 Black Acorn Cap Nuts, Stainless Steel 304 (18-8) Black Coating Acorn Nuts, 20Pcs-Pack
  M6-1.0 (x10) - to bolt the rack to the roof ($7)
• ~1/8 aluminum plate to bolt to the front for a fairing (Not completed yet)
• 3/16 plate- various tabs on the rack (tabs to connect rack to roof and high lift jack mounts)
• 3/8" 14 gauge tubing - for the connectors from the center tube to the bottom rails to make it more like a roof basket. ($14)
• Bolts and nuts for front fairing
• 39in compact light bar. - I found one on superbrightleds.com ($75)

I could only get 45 deg bends so the top loop was made from 8 different pieces. The guy that helped me bend these only had a 90 deg die, and he said would only be able to do about 70deg before it starts to kink.

 

That is the best rack I have seen. I am currently building one also, 2017 DCSB limited, but may change some of the design based on the way yours fit to the roof. I love it, it looks great. I have been scouring the internet looking for custom roof racks for our trucks. Glad I found yours.