Roof rack DIY

Covid-19 quarantine means DIY projects. So here we go.
I'm making a knock off roof rack following every company out there's design.



A band saw is making quick work of the rough cuts. Happy this is working out so far.







FINAL PRODUCT

 

Well at least you're honest. Interested to see your take on it. Or just sticking to a simple crossbar scheme?

 

Rough cut almost finished

 

Have you thought of using extruded aluminum bars for the cross'?

 

At most 40 pounds but it depends how many cross bars I decide to use. I'm thinking it's gunna be less than that weight

 

Shipping to Hawaii plus cost of the bars is roughly $250 for like 4 or 5 of them I think. At that price point and for having no real use, I didn't think it was worth it. Also I'm set on using steel for the side rails and I don't really want a mix of metals at certain points so I'm going full steel. A 20' long 1/8" thick 1"x2" c-channel is $40. Can't go wrong. If down the line I feel the need for extrusion I will look into options. This rack is almost exclusively to mount cargo containers for camping gear and a mounted road shower so I don't need the flexibility of mounting points at the moment.

 

Adjusting bottom line to contour to the roofline. I didn't like how the flat bottom line looked right next to the roof

 

Side rails cut to shape. Going to rough cut some cross bars and the wind fairing and call it a day. Not bad for the first day.

 

Looks fantastic- what thickness are you using for your side panels and fairing?

 

I decided to go with 1/8". The only issue I'm noticing is the flimsiness of the side rails. However I just need to get my cross bar measurements very precise to hold the side rails perfectly straight and it will be all right. 1/8" is plenty strong enough to carry a good amount of weight. The most I see myself putting on these racks is 100 pounds. Rtt will go on the DIY bed rack. Haha

 

Awesome, You've got me thinking this is going to be a spring project. As much as I want to support vendors on the platform I really can't see paying $600+ for a rack...

Are you looking at mounting up lighting or anything?

 

I haven't decided on lighting yet. I am rattle canning the entire thing in the hopes that I can drill new holes or weld new mounts on in the future and touch up fairly easily.

But yes, as a person who does everything myself I just couldn't see myself letting someone else do something for me that I could do so easily myself.

 

1) I think if a person has the equipment and time, it might be a great opportunity to innovate instead of outright copy. 2) coatings. I imagine in Hawaii it’s important to consider what your finish is going to be.

 

Cold galvanizing compound under whatever color he picks should do it.

 

How many gigawatts does that saw take?

 

Are the factory holes in the roof M6?

 

I like this! Good work op!

 

I’m in to see the finished product!

 

Hopefully it turns out good!

 

Update. Making mounting brackets. I now see why prinsu makes the adjustability for the side rails left to right and part of the rails of themselves. The water roof trim contours slightly outward in the front. This is how they are able to set the rack up perfectly straight front to back. I have however decided to let my side rails contour to the roof trim. I think it'll look unique.

The roof factory mounting holes are also slightly contoured as well so I had to hammer my mounting brackets to the correct pitch so they remain verticle 90 degrees