Roof Rack Build

[james-c]

Evening all... I have started building a roof rack for my 80 over the Easter weekend. The reason for building is that I couldn't bring myself to pay N$10,000 (650 pounds) for the roof racks available here in Namibia (front runner etc), when the materials would cost about 60 pounds.

Anyway, I modeled my design on this one: http://www.bajarack.com/toyota-lc-large

I used the following round tubing:
25mm (1 inch) diameter, 1.6mm wall, for the frame
19mm (3/4 inch) diameter, 1.6mm wall, for the cross beams
aluminium sheeting for the wind deflector

Dimensions of the rack: 1,320mm wide and 2,100mm long

Weight: about 26kgs

Here goes:
I started with the bottom frame:


And then added the cross members:

 

[Chris]

James, nice work, looking forward to the full build. You could throw a mattress on there and sleep out! Looks better than my bed.

 

[james-c]

Then came the top frame and the vertical upright supports:





I used a 25mm hole saw to cut the coping at ends of the tubing to form a snug fit.

 

[james-c]

Then a few licks of paint


I have some old roof bars which I used just to see what it looks like on Betsy (my cruiser):


Tomorrow I'll get some aluminum sheeting from the wind deflector. And I need to get some ideas of how to make the feet - I'll appreciate any ideas or tips on building feet for the rack.

 

[james-c]

Lol, yeah I was thinking that it would make a good sleeping place.. just need to build a tent, or just sleep under the stars

 

[warrenpfo]

Mooi man that looks the business.

 

[Chris]

Sweet! So how come they cost so much from the factory, eh?

 

[richrock]

That's fantastic. I'm struggling to find a roof rack here that won't break the bank. Unfortunately I don't have your welding skills!

 

[Gav Peter]

Hey James, have a look at Warren's thread HERE for inspiration on mounting feet for your rack

 

[moggy1968]

That's fantastic. I'm struggling to find a roof rack here that won't break the bank. Unfortunately I don't have your welding skills!

couple of options for you.

I've got some heavy duty roof bars from Halfords. Very strong, good wide feet and about £100 for a set of three.

did really well driving to the Gambia. then all you need is a basket to attach to it. easy enough to find a cheap 2nd hand rack you can cut the feet off now you don't have to worry about the width, or you could make a wood base to attach to the bars.

These days I have an upracks, which in it's most basic form is quite reasonable compared to other racks, although accessories are pricey.

 

[richrock]

Cheers Moggy, I'll definitely have a look into the halfords bars.

Has anyone got any experience with the Direct4x4 roof racks? Cheap but does that mean they are a bit rubbish? http://www.direct4x4.co.uk/titan-universal-black-roof-rack

 

[james-c]

Hey James, have a look at Warren's thread HERE for inspiration on mounting feet for your rack

Thanks. I saw that post and it inspired me. I made 4 of them feet and stuck them on the rack - nice and sturdy. I want to make another 4 so that I've got 8 feet holding it up. Heres a pick of me testing them:


Still need to finish them off and tidy them up a bit

 

[Gav Peter]

Very good James

 

[moggy1968]

yeh, you deffo need at least one more pair of feet there, 2 pair even better. nice wide feet though. Aim to position the feet over the C post if you can rather than over the span of the window frame

 

[clivehorridge]

I'd go for at least 3 each side, it's one thing I like about the ARB rack, nice wide spread too. Watch out for branches snagging the down clamp too. A capping would prevent that, unless you don't do too much tree bashing in the ruts!

 

[james-c]

yeh, you deffo need at least one more pair of feet there, 2 pair even better. nice wide feet though. Aim to position the feet over the C post if you can rather than over the span of the window frame

Thanks for the advice - I'll build accordingly. I'll probably add another 2 pairs since I have already half finished them, and that it gives better weight distribution.

 

[Brian the Sn@il]

Looks fantastic James !

 

[Aaron Schubert]

Nice work mate - this thing is looking good.

In regards to the roof rack, I believe the best design is to have a length of flat bar that runs the length of your gutters, which is welded to the top section of the roof rack. Then, you can use 3 - 4 clamps to secure it and be sure the load is as best distributed along the gutters as possible.

I've attached a photo in case my explanation above doesn't make sense!

Aaron

 

[james-c]

Yeah, I've seen those designs. The problem is that there is a slight curvature in the gutters and I don't trust my fabrication skills yet to match the curve.

 

[warrenpfo]

Cardboard is your friend