Thoughts on my expedition rack

The rack will come off once your remove the 8 bolts holding it on the bed rails..(two per end). It would take less then 5 minutes to remove them.

 

Since you've asked for opinions:

10 gauge only gets you .0095" thicker than 1/8 Wall. That's like the thickness of 2 sheets of paper.

3/8" Grade 8 fasteners are super beefy and are possibly overkill. I personally like Grade 5 as they are a bit softer and have a little more give to them than Grade 8. Grade 8 has a higher shear strength but is more brittle and will snap where the Grade 5 would absorb more. I agree with going SS fasteners. Nylocks are only good for one use. If you plan on repeatedly unbolting, Nylocks aren't the way to go.

Looks good though! What software did you design in? Did you run an FEA?

 

Thanks for the input! I ended up going with 10g, and yes, 3/8 is overkill but I tend to build stuff that way.

It can be either nylocks or standard nuts and lock washers lol but once someone sets exactly where they want their bars, there's not really any reason to undo the side and tops bars..But I could just included standard nuts and lock washers with the kit.. Depending on cost of the SS bolts vs grade 5, I may just do SS bolts, but the PITA part about SS bolts, if using SS nuts as well, they gull up and fuse one another.

I designed the rack in Solidworks

 

Yeah, I hear you - I like to over design stuff myself for unforeseen situations - I'm overly cautious and don't like to split hairs on designs, costs can add up though.

Yeah that's the issue with SS fasteners isn't it? You absolutely have to put thread lube on or galling will happen. Black anodized fasteners may be another option for you.

You could also have galvanic rust issues when using dis-similiar metals on your fasteners.

 

Yes Sir

 

Just trying to help and make a friend. I'll butt out now.

Nice rack though.

 

No you are fine, I greatly appreciate the feedback

 

Awesome work; jealous of your SolidWorks abilities!

It's definitely a unique design.

One thing that I've noticed with my bed racks, loaded with a roof top tent - is that the amount of movement and flex is surprising. I'd be concerned about the amount of deflection with the segment that rests on the top of the bed rails; loaded with a roof top tent, I could see the edge cutting into the plastic caps.

Good luck!

 

I see your concern but with the bottom feet resting on the top of the bed rails and having 4 bolts per upright, I don't think there will be much deflection, not saying its impossible lol...

I will also be designing and selling bed rail caps that will cover the complete top of the bed rails, this eliminating digging into the plastic bed rails as well as help spreading the load. So depending on what you will carry, there will be an option for this..

Tim

 

Ingenious!

 

Ok, went in for a bit to finish leaning up the parts and I dimple died the second upright. As you can see in the pictures, the tube will be welded to the tabs and both the sides and top center bars will be adjustable for anyone's needs.



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Here is the revised basket for those of you who were curious. And again it will be made from .1875 (1/8) aluminum.

 

Ok I have pricing on the aluminum basket now. The basket is $400+shipping. CNC cut and formed from 1/8" 5052 aluminum, dimpled died holes. $450+shipping for the basket that comes with 2 tube rails for the top to mount a bike mount, snowboard mounts or whatever it may be.

 

Well I had hoped to finish welding the parts tonight after work....But I received a call from the gf that someone had hit the Jeep after she just parked and waked inside....Who the hell hits parked cars in a decent open area?..

 

Just got home from finishing up on the rack. Here are finished photos minus being on my truck. (GF took the truck today so I could get a rental for her)

I will drop it off to powder coat tomorrow after work and I will have it back next week..

For those of you who are interested, please PM me so I can get a list going for a group buy.

 

Bump

 

Might want to make a new thread with a catchier title for people to look and add their name, just a thought and of course new pictures. Also you might want to test it out first to see weight ratings so you can post those too

 

I have a couple other threads already with pictures and different title names. As far as weight goes, I will be posting pictures of that as well, but with two guys standing on one upright, close to 400lbs, the uprights did not deflect any.

 

Thanks for all the feedback and interest everyone! I think it turned our great.

Here are a couple pictures I snapped quick this weekend. I didn't have time to take good ones but gives you and idea.

The group buy list has started and sounds like TXGnftr is first on the list.

 

PM me or head over to the Group buy to get on the list. 4 more and the process will start. Thanks for those who have found interest in the rack and or basket.