This week I finally made my rack bars. The goal was cheep, fairly strong ,adaptable and had to look ok. My need in the first place was some what goofy, this Jeep sits outside at home and at work for my wife. In the winter if the entire roof does not get brushed off some where in her drive the car is warm and a stop sign pops out of nowhere. The snow load dumps on the wind shield and wipers cannot handle it so its get out in traffic and clear it off.
By
xc204, shot with
FinePix S5000 at 2008-05-27
Parts list: (1) 10' chainlink fence top rail 1 3/8" od $9.95 Menards
(4) Clamp-on Tee's Item 95720 $2.99 ea Harbor Freight
These say for 1 1/4" od pipe but its really 1 3/8"
(1) Duplicolor truck bed spray liner $7.99 Advance Auto
By
xc204, shot with
FinePix S5000 at 2008-05-27
This photo is of the raw tubing and clamps the tube on the right is 1" rigid conduit od is 1 3/8 the fence rail is the same size this comes in handy for the first part of the construction the bars need to be bent down at each end to clear the roof top. Find a friend who is an electrician or go to a small elect contractor and use a 1" rigid bender to put a 1/2" or greater rise on each end. Mark a center line on the tube with a marker so you can keep the bends in line.
By
xc204, shot with
FinePix S5000 at 2008-05-27
1" rigid conduit can be used if you want sturdier .The tubes measure 41" front 38" back mine mount at the junction of the plastic to metal rail on my 2006 Sport. the Clamps have hollow allen set screws I drilled through these and put 1/4- 20 ss bolts in the ones on the cross tubes. A 1/8 " rubber pad takes up the fitment to the stock rail. I also put a piece of clear tubing over the 3/8-16 bolt that goes under the rail
By
xc204, shot with
FinePix S5000 at 2008-05-27
The clamps are like an erector set you could put two tubes in between the cross rails for a tire holder. I put provisions on rear bar for backup light. I may make a front bar with more rise for a light bar. I did not detect any wind noise at hiway speeds either.
By
xc204, shot with
FinePix S5000 at 2008-05-27
Next mount front hitch and clevis lift