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Boiler's Roof Racks Production Recap Page 9 & Weld Xbar
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=59&t=40168		 Page 9 of 10
Author:  Guest [ Tue Jun 09, 2009 11:07 pm ]
Post subject: 
TruLiberty wrote:
sick rack dude, is it possible to get this ordered with Hella's or something similar instead of the lights you used? look like CatEye Bike lights to me :(


They ARE Hellas...
Author:  Inc [ Tue Jun 09, 2009 11:13 pm ]
Post subject: 
ThunderbirdJunkie wrote:
TruLiberty wrote:
sick rack dude, is it possible to get this ordered with Hella's or something similar instead of the lights you used? look like CatEye Bike lights to me :(


They ARE Hellas...

and you could always buy your own specific lights.
Author:  TruLiberty [ Tue Jun 09, 2009 11:15 pm ]
Post subject: 
ThunderbirdJunkie wrote:
TruLiberty wrote:
sick rack dude, is it possible to get this ordered with Hella's or something similar instead of the lights you used? look like CatEye Bike lights to me :(


They ARE Hellas...


I've been nubbed.

and @Inc, all lights have the same wiring conn at the light?
Author:  Inc [ Tue Jun 09, 2009 11:21 pm ]
Post subject: 
TruLiberty wrote:
ThunderbirdJunkie wrote:
TruLiberty wrote:
sick rack dude, is it possible to get this ordered with Hella's or something similar instead of the lights you used? look like CatEye Bike lights to me :(


They ARE Hellas...


I've been nubbed.

and @Inc, all lights have the same wiring conn at the light?


I am far from an expert, but I would assume they are very very close if not identical. Someone please correct me if I am wrong.
Author:  Boiler [ Wed Jun 10, 2009 6:35 am ]
Post subject: 
Those are the lights I happened to choose to use for MY liberty's rack, they do not come with the rack itself. You can put any lights on it you want. Currently I'm not reselling lights.

Most lights just come with wires to hook them up, and some come with two wires already connected and sticking out. Either way, any lights should be able to be connected and routed through the rack.

I believe a customer should have pictures with hella optilux 1900's soon.
Author:  VoodooMann [ Wed Jun 10, 2009 7:00 am ]
Post subject: 
Indeed Sir!

by next wednesday if my calculations are correct
Author:  Boiler [ Thu Jun 11, 2009 4:55 pm ]
Post subject: 
To recap this thread:

Me (Chip): I'm a project engineer who designs all aspects of scissor lift machinery during my day job. At night and on weekends I am designing equipment for Jeep Libertys.

Tony: Tony is a CWI (Certified Weld Inspector) and is the fabrication foreman where I work. He is doing all of the welding and more than his share of the rest of the fabrication.

What we are offering for this roof rack: This rack is our first product offering for 02-07 Jeep Libertys (KJ). It is made of 6061-T6 aluminum and mounts to the factory roof rail mounting points. The rack weighs 26 to 34 lbs, depending on options selected. The floor of the rack sits about 1/2" away from the roof, and the sides of the rack sit 3" above the floor.

Pricing:
Base Rack---$435 Bare Aluminum + shipping
Front & Rear Crossbars (welded)---$90/pair
Front & Rear Crossbars (removable)---$175/pair
Light & CB Tabs---$5/each
Powdercoating or Anodized finish: PM for pricing

Payment types: We currently accept Paypal, money orders, or cashiers checks. Please PM me for an invoice before sending payment.

Shipping: Currently racks are shipping 1-3 weeks after reciept of payment. Racks are shipped fully welded in a big box...

Pictures of rack & options:

Base rack with light tabs:
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Rack with front and rear crossbars (welded): (new photo's soon)
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Rack with front and rear crossbars (removable): (only 1 shown in photo) These can be placed at any position front to back, to lock in your cargo.
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Rack being built in welding fixture:
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Interior passageways for wires on racks that get light tab options, free of charge upond request:
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My Jeep's rack wiring, ready to mount (wire, lights, etc. not included).
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Racks with light tabs can have a 3/8" hole in the bottom of the tube at each tab, to run wires into. Free of charge upon request.
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Wires exiting the foot to go through a hole in the roof. Interior routing holes free of charge upon request.
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My wiring installation. Currently not offered.
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Finished rack powdercoated and installed:
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I ran FEA (Finite Element Analysis) on my model when sizing my tubing. FEA is a tool used by engineers to calculate deflections & stresses in a target part or assembly. You create a mesh of lines and nodes, apply loads and supports, and the program calculates your deflections and stresses at each node. I used the ANSYS 10.0 FEA program and Autodesk Inventor solid modeler to do my analysis. Yeah, it may be a little overkill, but you can expect anything I build to have this level of attention put into it's design.

Basically I set it up so that a 300# load on any one point of the rack bottom would not 1) breach a safety factor of 3 for strength, or 2) deflect more than 1/4" (half the gap between the rack and the roof). I put the load on the center of one of the center tubes, and it easily passed both of those tests. Imagine a 300 lb. guy standing on one foot at the weakest position, and having no issues.

Next for a dynamic test I considered a 600# load spread over the center two tubes and recalculated deflection and stress with the same requirements. I thought this 600# test would reflect 200 pounds strapped in probably the worst case for the rack, and being put through 3G accellerations on the road (ie: rough bumps). It passed as well, as the images below show.

WARNING: The rack can handle a lot of weight, especially when standing still (loading, unloading). However, I'd recommend 150 lbs or less offroad, considering the owners manual rating for the Jeep Liberty roof. Also, driving with a lot of weight on the roof would require serious strapping and could hasten rollovers, handling oddities, and would catch more wind. I will not be held responsible for damage caused to your jeep or people due to overloading the roof.

FEA Mesh
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FEA Forces and Supports
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Deflection under 600# destributed over 2 center bars
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Von Mises stress under 600# destributed over 2 center bars. Von Mises stress is a method of calculating stress when concerned about yield strength.
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Author:  VoodooMann [ Thu Jun 11, 2009 7:42 pm ]
Post subject: 
(not to ruin your fabulous /thread post, but) did you end up extending the light tabs slightly to accommodate for the shock mounting some lights, such as the Hella Optilux 1900s use, or did you just reposition them so the weld wouldn't interfere?
Author:  Boiler [ Thu Jun 11, 2009 8:29 pm ]
Post subject: 
We raised them 1/8" to make them flush with the tube tops. You should be GTG. We get them "drilled" (read: CNC plasma cut...) to 1/4" holes, so you'll have to drill yours out. If you have a light with you, we can do it when you're here.
Author:  VoodooMann [ Thu Jun 11, 2009 8:35 pm ]
Post subject: 
We can drill them out while we're at it

I plan on bringing them so I can mount them up to see what they look like/hear how loud the wind noise from them will be on a long haul.

It's going to be my only long trip for a while where i will actually be able to tell what it's like at highway speeds.

Im wiring them on wednesday, so for now they'll just be poser lights :lol:
Author:  VoodooMann [ Sat Jun 13, 2009 2:24 pm ]
Post subject: 
My Rack Update:

ON the drive home, turned lots of heads

also, I didn't note ANY change in wind noise with the rack on, with windows up OR down! :shock:

it was quiet as the grave going down the highway, except for the very slight hum my tires make, and the light drone of my exhaust. (not very loud while cruising).

Looks Slick, First coat of primer is on, second coat/topcoat later

followed by pics in the 'post pics of your rig here' board
Author:  4WheelAholic [ Mon Jun 15, 2009 3:26 pm ]
Post subject: 
Boiler wrote:
To recap this thread:

Me (Chip): I'm a project engineer who designs all aspects of scissor lift machinery during my day job. At night and on weekends I am designing equipment for Jeep Libertys.


You design scissor lifts Huh.... You mean like this one? :lol:

Image

I couldn't help it this is a great picture!
Author:  Boiler [ Tue Jun 16, 2009 10:43 am ]
Post subject: 
The rack we did last week had welded front and rear crossbars:

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Author:  Rudy [ Wed Jun 17, 2009 10:22 am ]
Post subject: 
Quote:
You design scissor lifts Huh.... You mean like this one? :lol:

Image

I couldn't help it this is a great picture!

WTF!?! What is that for. Picking apples without getting out of your jeep?
Author:  djui5 [ Wed Jun 17, 2009 11:00 pm ]
Post subject: 
Rudy wrote:
WTF!?! What is that for. Picking apples without getting out of your jeep?


Photoshop :)
Author:  Rudy [ Wed Jun 17, 2009 11:41 pm ]
Post subject: 
djui5 wrote:
Rudy wrote:
WTF!?! What is that for. Picking apples without getting out of your jeep?


Photoshop :)

Really? Nice work...fooled me. :oops:
That would be pretty cool though. :roll:
Author:  tjkoen01 [ Fri Jun 19, 2009 7:39 am ]
Post subject: 
now that is how an engineer routes and terminates wires! beautiful!

Image
Author:  jeepmedic46 [ Fri Jun 19, 2009 1:34 pm ]
Post subject: 
Can't wait to see your rock rails. :)
Author:  Boiler [ Sat Jun 20, 2009 5:52 pm ]
Post subject: 
tjkoen01 wrote:
now that is how an engineer routes and terminates wires! beautiful!


Thanks :D

icefisher45 wrote:
Can't wait to see your rock rails. :)


That makes two of us.

We had to make the 1/2" height change to the side rails due to UPS and Fedex thinking we were a smidge to big. Well we've been reworking all of our fixture and jigs. We finally finished the brunt of it and today we cut a few racks worth of parts and worked on our current order. Once we're done with this one, I'll be back on my rock rails and gas tank skid. Should be early this week. I got the material for the main tube of the rock rail a couple weeks ago and cut it...it's going to be sick. We're going to make the strongest and most rigid rock rails out there. Except for maybe Inc's....maybe. I really can't wait.
Author:  tumanator [ Thu Jun 25, 2009 12:05 am ]
Post subject: 
My jeep didn't come stock with foglights so I'm not sure how the stock wiring is done. Is that wiring panel under the kickboard stock or did you have to fabricate that up? I'm going to add lights (it's on my list of stuff to keep my bank account dry) and I'd prefer a more professional wiring panel like that myself, over some of the stuff I've seen in pics. Being an Aircraft Tech for some reason I like to keep my wiring in a bundle (sorry for the pun I couldn't help myself.)
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