My Custom PrInSu Roof Rack

I recently finished a roof rack that has been an idea in my head for sometime now. I am a firm believer in "don't just talk about it, be about it", so when I had this idea I couldn't let it go. Wanted to bring you through a little journey of my rack build. Thank you to Zach from PrInSu Designs for working with me and helping making this happen.


The main idea was to have a slim line roof rack to support accessories on top and host a roof light bar in the most sleak fashion. I knew from the start I was going to use the PrInSu roof rack as a base. I noticed a couple custom racks made for a 50" light bar, so I started thinking custom was possible. After back and forth emails with Zach, I had to start figuring out the dimensions to bring this idea to life.




This is my idea on paper



And here is the dimensions I came up with needed. I decided to give myself extra space that i can trim to my needs once I was able to see how everything lines up once assembled.




I sent Zach the dimensions and waited for the rack to arrive.


When the rack arrived the first thing I did was bolt two cross bars together with the side rails and layed it up on the truck! Couldn't wait to see it with the light bar.





Then had to throw all the accessories on top to finally see what it will look like when complete. Nothing is bolted down, you would do the same





Then became time to start the fabrication. A combo of no garage and the winter weather turned my spare bedroom and kitchen into a workshop





First problem arrived when I realized that with a curved light bar, the mounting arms can not be mounted behind the bar on a flat surface. The curve only allows it to be mounted above or below the light bar.




Needing it to be mounted behind I grinded down the mounting arms, then was able to mount it as needed. I asked to not have any holes drilled for fairing or light bar. That way I can position them to my liking. I found the best position for the light bar, drilled holes, and bolted the cross bar that will hold the light bar.






Next was to trim the side rails. I wanted to take the curve of the light bar and follow that line all the way out to the side rails.





I wanted to use my chop saw but the metal blade I had for it had a good wobble when I turned the saw on. So I had to resort to an angle grinder. Cleaning the cut with a flap wheel really made for a clean result.







Visually checking it out, step by step






Now came time to figure out mounting the accessories that will live on the rack. The accessories will be a Pelican rifle case transferred into a storage box, got that idea from Zach himself. A set of TRED recovery ramps, and a 4 gal. rotopax fuel can.

Before getting the rack installed and buttoning everything up, I decided to figure out the TRED mounts. Got the idea of using a piece of angle iron as the base from geekhouse23's build. Then used long bolts to thread the TREDs. For now washers and wing nuts will hold them in place.






Time for install. I filled the tap holes in the roof and the aluminum spacers centered over with rtv silicone and bolted down the rack. All the cross bars were preassembled including the light bar to the side rails.

I ran the light bar wire harness down the passenger side window.



The 4 gal. rotopax fuel can was an easy mount with the 4 gal. roto mounting bracket. The TRED mount was prefabbed and ready to go.

Last up to mount is the Pelican box. I picked up 2" square U bolts which fit the crossbar perfectly!




Quick look of everything kept in the Peli box







Finished the rack and accessory install just in time for a little snow storm. Come morning I went out for a drive feeling invincible





Once the storm passed I started on the custom fairing. Ordered some black plexi glass and started sizing it up with cardboard.




Decided to paint the carboard real quick to visually see what it would end up looking like. Once I did that I realized i may want to fill in the space on both sides of the light bar.





Plexi glass showed up so I picked up some hardware and started fabbing. First order of business was the fact that I was out of T nuts from the rack order, so I made some T bolts. The rest just fell into place after cutting out the fairing.










Very Stoked with the turn out of my custom rack.
Thanx again to Zach at PrInSu Designs for working with me and making a great product. This rack is sleak, strong, and versatile.
If your in the market for a roof rack checkout http://www.prinsudesignstudio.com/

 

subbed..... great job man that looks incredible! Very impressive especially bc you did it out of your spare bedroom/kitchen hahaha.

 

Great job

 

Great idea on the bar mounts

 

Awesome job and amazing write up. Definitely subbed.

Thanks for the shout out too!

 

if i could do a set up like this i wouldn't really need a bed rack. how long is that pelican case? I have one on my bed rack and am wondering if i would be able to rotate it and run it along the top of my access cab. I thing the one i have is 40"-42" long.

 

Great write up. Turned out awesome!

 

so.much.win.

 

Nice job. I'm curious why you used square U bolts on the Pelican instead of the T-slots on the cross member. I've got a set of racks on order from Zach and reading your post makes me feel like a little kid when Christmas is still weeks away haha. I can wait to get mine and start adding my gear to them.

 

There is allot of strength in using U bolts. The Pelican box is heavy and takes the brunt of the wind drag. I feel good when I'm going down the highway that it's definitely secured to the rack. The T slots are very versatile but only allows you to thread up to 1/4", which is fine for other applications but as far as the Peli box I wanted it to be extra secure, and it was easily done with the U bolts.

 

Sick!

 

Wow. That's all that can describe the work done for the rack and great writeup too!

 

Awesome, looks good. I finished up mine yesterday, pretty excited that I finally have a place for everything. I'll need to revise a couple of things but otherwise it's solid. Thanks for the pics that lead me in the right direction.

 

looks good man!

 

Thanx for all the positive feedback. I actually cant wait to see what you guys are doing to your PrInSu racks. Feel free to post up ideas or pics!

 

No pictures of how everything looks like on the rack (same as Chux besides a black case)

But heres how I made my mounts, I was trying to figure how I could mimic your setup but I only have the standard bars (I should have just got the HD ones) So I ended up just using flat pieces of aluminum, I wanted a sheet but couldn't find anything local




Incase someone wants a cheat sheet of what to buy

Roto Pax
(2) At least 3' x 1.5-2" piece of aluminum strips
(4) T-slot nuts (I used 5/16-18 square nuts and slimmed down 2 sides)
(4) 5/16-18 bolts with both flat washers and lock washers

TRED
(2) At least 3' x 1.5-2" piece of aluminum strips (I went with 2" since I was drilling 1/2" holes in the center)
(4) 6" x 1/2" threaded rod? (I used 2 1ft pieces and cut in half)
(8) 1/2" nuts
(16) 1/2" fender washers
(8) 1/2" lock washers
(4) 1/2" Wing nuts
nut/lock/washer/aluminumstrip/washer/lock/nut/washer/treds/washer/wingnut on all 4 corners

All I need to do now is drill holes for the middle cross bars to eliminate some of the slap that I get on bumps. Still looking for a lock option besides a cable for the TREDs

 

This thing is amazing... gimme!

 

Chux - Where did you source the Pelican Box from? Thx!

 

Amazon
http://www.amazon.com/gp/product/B001CWPA6O/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1

 

Moar rack pics