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Low Profile Rack For Shell

Discussion in 'Tonneau Covers, Caps and Shells' started by AVGeek, Nov 5, 2020.

  1. Nov 5, 2020 at 8:32 PM
    #1
    AVGeek

    AVGeek [OP] Well-Known Member

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    Boulder City NV
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    2011 Barcelona Red Reg Cab 4WD
    I have narrowed down my choices on the shell I want to get for my 2011 regular cab. I’m planning on ordering new, since used caps are impossible to find for the RC. I’ll be ordering the rails in order to install some sort of rack, the primary purpose of which will be to mount lights. I may also eventually add a high lift jack, shovel and maybe the Maxtracks (this truck is primarily a daily driver, but will see some light off road use). The truck is stock height, and. Have no intention to lift it, especially since I want to make sure it will still fit in the parking garages here in Vegas if I ever go back to work in Live Events here.

    So what would be a good, reasonably priced rack? Also, what would be a good way to route the wiring for the lights?
     
  2. Nov 27, 2020 at 5:49 PM
    #2
    bushman31

    bushman31 Well-Known Member

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    Draper, UT
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    Old Man EMU suspension, 33" tires, 4.56 gears, Leer shell, airlift airbags, Fab 4's rear bumper and tire carrier, and some other shit.
    Look at Frontrunner Slimline ll. I have one on my shell and another on the cab. I don't mount my lights on top, so I can't help you out there.
     
  3. Dec 7, 2020 at 7:58 AM
    #3
    Mojave4x

    Mojave4x Active Member

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    Detroit TrueTrac both diffs, re-gear 4:30, Wheeler's 8 leaf, OME 881, JBA UCAs, Bilstein 5100 all 4 corners, All new u-joints & ball joints, new LCA bushings
  4. Dec 7, 2020 at 8:42 AM
    #4
    AVGeek

    AVGeek [OP] Well-Known Member

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    I like that DIY approach. I used unistrut for tie down rails in my last truck (Ford F250) since it had limited points. I kept the rails, so I could re-use what I have so far.
     
  5. Dec 11, 2020 at 1:53 PM
    #5
    T MAC

    T MAC Well-Known Member

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    Tim
    Foothill Ranch, CA
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    I went DIY approach as well after seeing the price of available units (which are largely just waterjet aluminum side plates with stock aluminum extrusion cross-members anyways). This cost me just under $200 in material, and I even received it with lengths cut and ends tapped that I requested - I literally just had to bolt it together. I did some machine work on the awning brackets.

    I apologize for the crappy pics, taken last night when I put it together.
    upload_2020-12-11_13-52-13.jpg

    upload_2020-12-11_13-52-53.jpg

    upload_2020-12-11_13-53-31.jpg
     
    TroutBum likes this.
  6. Dec 21, 2020 at 7:57 AM
    #6
    MY50cal

    MY50cal ---- Tread Lightly ---- Leave No Trace

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    Mojo
    Camden County, NC
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    Yep.
    What can you tell me about that piece used to mount the awning?
     
  7. Dec 21, 2020 at 9:36 AM
    #7
    T MAC

    T MAC Well-Known Member

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    They are 8020 alu extrusion framing brackets I had laying around. Ended up working out nicely and looks clean.

    Two red holes circled below were countersunk so that mounting screws would sit flush with the plate face. The blue hole circled below I milled a couple mm into a slot to accommodate the 48mm awning t-slot width.

    upload_2020-12-21_9-34-3.jpg

    Also snagged a nice gun case from harbor freight on sale. I drilled four holes in the bottom of it, and run 6mm hex bolts in the crossbar alu channels, and rubber/fender washers w/ nylock nuts. Now I have all my camp gear organized and ready to go, takes two minutes to toss it on the truck. I will probably pick up another case for bike gear and tools. This is more efficient (fuel wise) than the big thule carrier I would toss on top for trips.

    lQ1mQ9nbVU9w22yQ8vfJ1tFTFALFtwAvnDBZHuFv_4278c20fe3db1a0ec73906742ed3137b38ce1dc3.jpg
     

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    Last edited: Dec 21, 2020
    MY50cal likes this.
  8. Dec 21, 2020 at 1:08 PM
    #8
    AVGeek

    AVGeek [OP] Well-Known Member

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    Looks great! So it appears to all be 8020...which size tube did you use?
     
  9. Dec 21, 2020 at 1:40 PM
    #9
    T MAC

    T MAC Well-Known Member

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    Thanks man. I actually didn't use 8020, I used extrusion from www.tnutz.com. 100% compatible with 8020 components though , just a good bit less expensive than 8020 itself. I went with 1in (or "10 series" per tnutz). It is pretty thin/low profile, and still strong enough for me to hang off of it (all 155lbs of me). Conveniently the tracks installed on my shell worked perfectly with the 1in/10series t nuts, so I just used 2x2 corner brackets from tnutz to attach to the shell. Between CAD design, ordering components, and assembling the rack, I probably have 5hrs total in this project.

    No wind noise, or increase in drag/decrease in mpg from this rack.
     
  10. Dec 23, 2020 at 9:45 AM
    #10
    MY50cal

    MY50cal ---- Tread Lightly ---- Leave No Trace

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    Yep.
    Ha, that's exactly what came to mind when I first saw your pic.

    Oddly enough, just used two of those to mount my antennas (CB/HAM) - enlarged and pulled the center hole and mounted, worked out really well.

    Been going around different mount options for the awning, not sure why it didn't click to use these. Thanks man!
     
    T MAC[QUOTED] likes this.

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