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

Boiler · **Posted:** Fri Apr 17, 2009 2:44 am

Well, I've switched focus to electrical install, and Tony has been at a welding conference, so Tomorrow will be the first we've done much this week. I've got to work, but he's off. He tells me he's going to finish the last few parts, drill the holes for my wiring route, and then weld it.

We'll see, thats a lot to do in one day, and he's got some things to get done for a welding contest on Saturday.

Today I did make a little formed plate that I'm going to mount two fuse blocks and up to at least 6 relays on, and it mounts inside the little fold down panel under the steering column. I'm planning on mounting my switches to the top left portion of that panel too, which will allow me to have less wires moving when the panel opens. It will also allow me to wire up a good portion of it at the workbench. I was hoping to get my wire by tomorrow, but it looks like it will be monday. I guess I can have all the switches and relays and fuses mounted and ready. I ordered 200 ft of white and red 14ga SAE thick crosslinked (275 degree) wire to run the lights, and like 8 different colors of the thin xlinked SAE 16 ga for the circuits. I'll have a lot left, but I'm sure I'll find a use for it. I even thought about buying some big spools and selling it in small quantities. I think most people will just grab the junk stuff they sell at auto parts stores though...

Well here's to hoping I have pictures to show tomorrow. I'm guessing it will be Sunday or Monday though.

0311_DoC · **Posted:** Fri Apr 17, 2009 1:07 pm

cant wait to see your relay/wire set up....

Boiler · **Posted:** Fri Apr 17, 2009 1:51 pm

I saw someone either on this board or KJcountry mounted a similar fuse block or two on that fold down panel, and then relays across the plastic brace. Instead of trying to drill those holes for the relays, I formed an aluminum sheet to basically mirror that brace when folded up. It pulls out easily (when not wired up :wink:

) so initial assembly & local wiring should be a snap.

Kugellager · **Posted:** Sat Apr 18, 2009 10:41 am

Boiler wrote:

I saw someone either on this board or KJcountry mounted a similar fuse block or two on that fold down panel, and then relays across the plastic brace. Instead of trying to drill those holes for the relays, I formed an aluminum sheet to basically mirror that brace when folded up. It pulls out easily (when not wired up :wink:

) so initial assembly & local wiring should be a snap.

That was me...I didn't drill any holes for the relays...I just used self tapping screws to attach them to the plastic. There is about 1/2"(3/4"?) or so of space behind the plastic so the screws won't interfere with any of the wiring bundles.

There are several photos of my wiring and how it hass changed as I have added accessories over the years in the link in my sig.

John
];')

Boiler · **Posted:** Sun Apr 19, 2009 3:20 am

Actually my harness seems to be smushed up against that plastic for at least half the cross member. Either way I like this setup, as I can wire it all out of the jeep, and the wires don't have to flex when I open it.

Well, this will be true once my wire gets here....

LIV42DY · **Posted:** Thu Apr 23, 2009 8:48 pm

Any updates, or a few pictures :lol:

zzack92 · **Joined:** Mon Jul 28, 2008 6:50 pm **Posts:** 371

LIV42DY wrote:

Any updates, or a few pictures :lol:

X2

Boiler · **Posted:** Fri Apr 24, 2009 10:36 am

Been snapping a few pictures as we go, but I haven't taken them off the camera yet. Yesterday we got the rack on my roof and basically polished it. Tony wants me to just clear coat it and show it off natural aluminum. It almost matches my OEM silver Jeep. I think I'm going to do a black hammertone powdercoat though.

I'll be taking it with me to the Ohio lift party tomorrow so y'all can check it out. Probably Sunday I'll start the flow of pictures.

One thing we had a hiccup on was the front and rear slider crossbars. The little knuckles I designed required welding a thin hinge to a thick tube, didn't work out very well. We're going to attempt to use 3M VHB 2 sided tape. I've used it for stuff here at work in the past, its some sick stuff. Should work well, but I'm going to test it out on mine first. Probably get that done next week. If it doesn't work, I'll be back to the drawing board.

tommudd · **Posted:** Fri Apr 24, 2009 12:15 pm

will be interesting to see it ! Do some side by side comparisions :lol:

JeepinJarhead03 · **Posted:** Fri Apr 24, 2009 3:42 pm

if theres no pics it's just imaginary!!!

LIV42DY · **Posted:** Fri Apr 24, 2009 11:50 pm

tommudd wrote:

will be interesting to see it ! Do some side by side comparisions :lol:

Tom will be the first to see the pictures, if I was closer I stop in and visit :wink:

tommudd · **Posted:** Sat Apr 25, 2009 12:06 am

LIV42DY wrote:

tommudd wrote:

will be interesting to see it ! Do some side by side comparisions :lol:

Tom will be the first to see the pictures, if I was closer I stop in and visit :wink:

Hopefully we will see it up and personal tomorrow, will be some pics I am sure since cdiekans will be there

Boiler · **Posted:** Sat Apr 25, 2009 12:15 am

Well, the VHB was crap to hold the knuckles together. It sucks for static loads. It will hold them on long enough to come show you guys what I'm doing, but we're going to use screws (Monday) and if that is no good, we're going to make our own hinges.

I've got my poser lights (not wired) on it, and ready for the drive to OH. Tony is starting to put #2 together tomorrow while I'm gone. Also this week we're going to work on some other options for the KJ roof, and then we'll put its design to bed. I am probably going to make a "nightmare" rack for one of the guys on here, then move on to the next project.

Sunday night I'll put all of our development pics on, and the un-coated rack, and then late in the week I should have final powdercoated & possibly wired pics.

Boiler · **Posted:** Sun Apr 26, 2009 12:32 am

Well, here are the pics. It has no finish yet. Everyone is telling me to just clear coat it, but I'll probably ignore popular opinion and do a black hammertone powdercoat.

Everything worked out pretty well. The crossbars at the end are a CAD image, as I've got a little fixing to do on the hinge this week. Will update those later.

Before welding:

Holes for wiring:

501 · **Posted:** Sun Apr 26, 2009 12:36 am

Looks GREAT Boiler, now the real question on everyone's mind......................... HOW MUCH!!

zzack92 · **Joined:** Mon Jul 28, 2008 6:50 pm **Posts:** 371

lookss sick!!

Boiler · **Posted:** Sun Apr 26, 2009 9:12 am

The rack is $435 bare aluminum, plus shipping. Wiring holes & light tabs options that are included for no additional cost.

The front and rear adjustable crossbars (removable) will probably be about $175 for the pair, unless our final design changes the price, but I don't think it should. I'll update pricing for them when we have a final crossbar option design.

We can also do fixed, welded crossbars, flush with the top of the side rails. They would be located directly in front of the rear bend, and behind the front bend. We are offering the pair of fixed crossbars for $90. I'll show them in CAD soon.

LIV42DY · **Posted:** Tue Apr 28, 2009 12:07 am

Outstanding job!!!

Competition has arived.. and afordable

03CDKJ · **Posted:** Tue Apr 28, 2009 12:10 am

I think since my pics are being used for advertising... I should get a HUGE discount! :wink:

KJ in CO · **Joined:** Thu Apr 09, 2009 4:06 pm **Posts:** 346

WOWZA!!

that rack is the tops! I am puttin that thing up on the list.. are you making them upon request?

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

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