Custom roof rack

Hey guys,

Thought I'd post this in case anyone is considering a diy rack. The primary materials I've used are aluminum extrusions and connectors from a company called 80/20 inc. I made the feet out of fiberglass. They could, I'm sure, be made from metal but I'm more comfortable working with composites. This is a very robust system and could easily support a roof top tent. I've made it with the cab overhang to better carry my sea kayak and am planning to install a solar panel up there at some point.

 

That looks awesome man. Great job

 

Thanks, I was a little reluctant to start blowing holes through my new cap but I'm very happy with it.

 

I was the same when i installed the rack rails. Dont know if your rack lines up with the cab roof weather gutter but incase you didnt already know theres some pre threaded holes under there you could use for extra support.

 

I don't know if access cabs are different but there are no pre threaded holes anywhere up there on a 2016 access cab. I found out the hard way.

It has them now though.

 

Nice! I just placed an order for 80/20 parts last night - making an interior rack to sit inside my canopy.

 

Yah the threaded 6mm holes are only on the double cabs. There for the factory rack. I thought about using those but ended up just through bolting to the cap.

The 80/20 stuff is fun to work with. I also made a couple of rolling tool chests with it.

 

Also,

For you guys thinking about making something out of these extrusions, 80/20 has an e-bay store where you can get some good deals.

 

My god, I almost threw up looking at this! I thought you drilled holes in the cab at first.
That looks nice and clean!

 

Never.
She's so pretty(except for the front end)! No penetrations through the sheet metal.

 

This is really cool! What was the cost of this project? Their prices seem to be steep once you add everything to the cart lol.

 

Yah, they get you on the small stuff, but once constructed, it is versitile. Everything slides to whatever position you desire and adding on is up to your imagination. Because the profile has the ability to instal
sliding nuts on all 4 sides you can mount lights, high lift, anything you want.

 

I think I ended up at about $400 for this project.

 

Found some pics of the tool chests I made

 

8020's prices for corner brackets are insane. $4.10USD for this? https://8020.net/shop/4101.html I'm planning on grabbing these guys at 1.54CAD (3.5 times cheaper) instead: https://www.homedepot.ca/en/home/p.1-12-inch--zinc-corner-brace-4pk.1000773638.html. Can you think of any reason not to?

 

I agree with you on the price. The 80/20 bracket looks to be bigger and will be higher quality. I think the cheaper ones would probably work. One thing to consider is that The t slot profiles are made with a slight inward facing bevel so that when you fasten on a connector and fully tighten it ,the connector contacts the outer edges of the profile first, making for a more solid connection and in effect keeping the bolt from backing out over time. So what I'm saying is that your corner bracket should be as wide as the t slot profile to take advantage of this design feature.

 

Awesome idea. Brains smoking already. They have some really great projects on their site.

 

is that 1.5" x 1.5" extruded Al? not too much deflection under load? looks really nice

 

Yes it's the 1.5". It's a burly extrusion. I carry a 17' sea kayak up there no problem. It could easily handle a roof top tent.