Boiler's Roof Racks Production Recap Page 9 & Weld Xbar

Inc · **Posted:** Mon Mar 02, 2009 2:36 am

You may hold the record for longest posts ever on LOST Marty.

Rock Lizard · **Posted:** Mon Mar 02, 2009 2:45 am

Inc wrote:

You may hold the record for longest posts ever on LOST Marty.

I made a shorter one just for you in your bumper thread. :twisted:

My short posts always seem to get interpreted wrong, so I like to clarify and make sure I put everything on my mind down.

Inc · **Posted:** Mon Mar 02, 2009 2:53 am

Rock Lizard wrote:

Inc wrote:

You may hold the record for longest posts ever on LOST Marty.

I made a shorter one just for you in your bumper thread. :twisted:

My short posts always seem to get interpreted wrong, so I like to clarify and make sure I put everything on my mind down.

Makes sense, and I don't blame you.

Boiler · **Posted:** Mon Mar 02, 2009 10:21 am

rescu2000 wrote:

I hope Boiler AND RL continue making great stuff!

I've not made anything yet. I wish my computer could print out aluminum racks though.

tjkj2002 wrote:

Well I don't think it was since he was asking for detailed specs from owners of the said rack just about a week ago and now he has a design almost identical.There's many ways to make a rack.It wouldn't be a big deal for his personal one-off use but marketing them is pushing the limit there.

I asked tommudd "what diameter are those rails". It was a curiosity. If there is one thing I'm going to do better than most is size tubes. I do it as part of my job, and have had posts on here doing exactly that. See my earliest posts, I don't have that many yet. I would never make a product and just build it based on someone elses tube size. I typically have minimum tube size calculations for anything structural that I design, and I betcha you won't find more than a handful of other builders doing that.

You can ask Tom about it if you think I was asking for knockoff details. Apparently other people were though. Whats funny is you guys actually give out the tube diameter and gauge right on your website...

To Marty: I appreciate the post and your input. You definitely know more about the business side of it than I do. I'll take any constructive advice from you guys (RL) I can get.

XC204 · **Posted:** Tue Mar 03, 2009 2:22 pm

Hows that proto coming ? need to get your hands dirty!

Boiler · **Posted:** Tue Mar 03, 2009 2:45 pm

Ha ha, yeah I know. I've actually got a ways to go before cutting anything. I'm going to try to nail down my model & finite element analysis by the end of this coming weekend. Once I get that done I'll finish drawings, get my bent parts, and draw & tack up a fixture. THEN I'll make the prototype. The guy doing my welding has his welder being serviced atm anyway. Hopefully I don't have to buy us a new one (yet). My wife won't be too keen on that idea.

I'm hoping to have prototype built, fit, and be making drawing & fixture corrections by April 1 or so.

yodejt02 · **Posted:** Wed Mar 04, 2009 11:03 pm

Boiler if you need a libby to test a prototype I volunteer. Just up the road in Fort Wayne, Indiana!

Boiler · **Posted:** Tue Mar 10, 2009 12:47 pm

Progress is being made, got the fixture and assembly done this weekend. Drawing option jigs, locating parts, buying material this week. Stress analysis done. Current rack weight: 24 lbs.

riptricket · **Posted:** Tue Mar 10, 2009 1:17 pm

I would connect the front and rear ends... that way nothing will slip out.

Boiler · **Posted:** Tue Mar 10, 2009 3:06 pm

I'm doing that as an option

USAFCOP · **Posted:** Wed Mar 11, 2009 8:28 pm

Inc wrote:

How creative can you be with a roof rack anyway? You basically take the stock rail design, make them steel and add some steel cross bars.

I have never been a fan of how the RL one's side rails seem to angle out instead of straight up and down. I would make the side rails parallel to each other.

I am a fan of this design because of how low it is. I only need some bars to hold 2 fuel cans on the very rear of the roof, so this will be the design I go for if I make or have someone make mine. Unless I just modify the stock metal ones to work. I know they'll hold the weight no problem because I had the fuel cans up there already, plus a massive roof rack.

The more people out there making products for the KJ/KK community the better.

The lower rack is the sport rack and is for sale by RL as well...

JJsTJ · **Posted:** Wed Mar 11, 2009 9:36 pm

I wasn't gonna run a roof rack any more on my SFA but that "Nightmare" rack would be on my KJ if I could afford it. That thing is killer.

just a note to anyone wondering about the factory roof nutserts and what they do when you smack your factory rail against a canyon wall..... They pop right out of the roof leaving a couple nice gaping holes that you have to figure out how to fill. ask me how I know.....

tjkj2002 · **Posted:** Wed Mar 11, 2009 9:40 pm

JJsKJ wrote:

I wasn't gonna run a roof rack any more on my SFA but that "Nightmare" rack would be on my KJ if I could afford it. That thing is killer.

just a note to anyone wondering about the factory roof nutserts and what they do when you smack your factory rail against a canyon wall..... They pop right out of the roof leaving a couple nice gaping holes that you have to figure out how to fill. ask me how I know.....

So does USAFCOP :lol:

,reason for the sport rack on his KJ that uses 3/8" bolts for the rear mounts with rather large washers.

Inc · **Posted:** Wed Mar 11, 2009 11:05 pm

USAFCOP wrote:

The lower rack is the sport rack and is for sale by RL as well...

Where do you think I got the pics? :wink:

USAFCOP · **Posted:** Thu Mar 12, 2009 11:07 pm

tjkj2002 wrote:

JJsKJ wrote:

I wasn't gonna run a roof rack any more on my SFA but that "Nightmare" rack would be on my KJ if I could afford it. That thing is killer.

just a note to anyone wondering about the factory roof nutserts and what they do when you smack your factory rail against a canyon wall..... They pop right out of the roof leaving a couple nice gaping holes that you have to figure out how to fill. ask me how I know.....

So does USAFCOP :lol:

,reason for the sport rack on his KJ that uses 3/8" bolts for the rear mounts with rather large washers.

I didn't bash the top on anything, I just got too twisted on the rocks.... Plastic flys too... L\ooked like beverly hillbillies how we tied it back together to get it home... That was a fun trip....

Boiler · **Posted:** Sat Mar 21, 2009 2:09 am

Just an update. Progress on getting things rolling has been slow, but we made a check jig for the formed parts and sent it to the tube bender today. He'll be doing them next wednesday. I've also plasma cut all the feet and flats used on the fixture. All material is on order and on its way.

Next Friday we'll be building the fixture and we plan to finish it and start coping tubes on the weekend. Probably will have a welded rack in 2 weeks.

Also for those of you that thought I should close in the front and rear with an upper tube, here are some screenshots of how I'm going to do it. Its pretty cool. It is totally removable, available after the fact, and is adjustable to fit whatever you're carrying.

Side view shows that the upper crossbars are even with the side rails, good for carrying oversized flat stuff.

Using HELLA FF75's would make the side and end crossrails the tallest things, keeping the lights below things like a sheet of plywood. Any type of light should be mountable though.

Machined, hinged knuckles are tightened with two 1/4-20 armor coated socket head bolts with stainless lockwashers. This allows them to be loosened, adjusted to hold whatever you're carrying, and retightened.

Finally, we're considering building the "Nightmare" rack as well. We're meeting tomorrow to discuss.

LIV42DY · **Posted:** Sat Mar 21, 2009 8:14 am

Keep up the good work. keep us updated.

501 · **Posted:** Sat Mar 21, 2009 10:16 am

Can't wait to see the final product and what your prices are.

Boiler · **Posted:** Tue Mar 24, 2009 1:31 am

USAFCOP, are you saying that the roof flexed more than whatever rack you had on it, causing a mount to rip out? Interesting...

Boiler · **Posted:** Mon Mar 30, 2009 8:55 am

Well, jack#%$& got done this weekend...

Today I've got 3 guys making parts for me (I'm at work) so hopefully this week we'll get something welded up. Everything is coming along fine, just getting rolling hasn't been easy.

I meant to bring my camera to work today and show where we're at but I forgot it in my "I'm late!" rush this morning. Will try again tomorrow.

Boiler's Roof Racks Production Recap Page 9 & Weld Xbar

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