Here's an attempt on the write up:
1. Roof rack
- I removed the existing rack per a prior post, exposing the bolts/holes that hold down the factory rails.
- Measuring the holes, drew up some "feet" out of plate steel.
- Drew the rectangle feet, smoothed the edges and drew out two bolt holes for each foot using Corel Draw. Saved the file as a *.dxf file (I'll share it but dont know how to attach...). Its two drawings, one front and one rear.
- Using a Hypertherm 45 plasma cutter connected to a 15x36" CNC table running Mach software and a floating Z axis, I cut out the four feet.
- the feet were placed on the roof and I measured out the rack. The rear of the jeep is narrower than the front. I was surprised at that and decided to just match it vs forcing a square rack.
- Using some steel rectangle tubing I had in the garage, around 2"x.75"xlength, I cut out the "square" frame. Its not really square as the front bar is several inches longer than the rear bar.
- The frame was tacked up and set on the roof.
- Feet were cut, I forgot to calculate the vent position on the sunroof but just BARELY lucked out...
- the frame and feet were tacked welded using a 220v Miller MIG welder running regular (not flux) wire with argon.
- The floor was finished with small square tubing, roughly 0.75" square .120 wall and the entire thing welded and quickly grinded/sanded/painted. I have the Raptorlining to spray it next, but havent got that going yet.
2. Bike rack
- removed spare tire mount.
- welded 1and3/4" .120 wall tubing a few inches out through the spare tire center cap to the tire mount.
- Cut another piece of tubing just bigger than the first to slide over.
- unbolted hitch mountrack top (performancebike) and cut some rectangular tubing for the vertical mast. Drew"I <heart> Guns" on the CNC machine and cut the motivation out of the rack.
- bolted everything up.
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