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 Post subject: 30$ Rack Bars Done
PostPosted: Tue May 27, 2008 10:01 am 
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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.Image
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

Image
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.
Image
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

Image
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.
Image
By xc204, shot with FinePix S5000 at 2008-05-27
Next mount front hitch and clevis lift

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Last edited by XC204 on Wed Jan 21, 2009 10:10 pm, edited 4 times in total.

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 Post subject:
PostPosted: Tue May 27, 2008 10:18 am 
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Looks really nice. Great job! :)

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 Post subject:
PostPosted: Tue May 27, 2008 9:01 pm 
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niccce like the look of the cheap bars
way to go
i might look into "borrowing" that idea for my roof

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 Post subject:
PostPosted: Tue May 27, 2008 9:27 pm 
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This might also work on the Renegade with the round roof bars if you lose the rubber pad.

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 Post subject:
PostPosted: Tue May 27, 2008 9:51 pm 
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nice, i'll have to keep this in mind when i get some for the wifes kj

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 Post subject:
PostPosted: Wed May 28, 2008 1:54 am 
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That is great. Looks strong, clean and very professional. I may have to "borrow" this one as well for some extra support up front for my rack.

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 Post subject:
PostPosted: Wed Jun 04, 2008 1:42 am 
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Very Nice, Did you find the clamps at Harbor Freight or did you have to order them?

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 Post subject:
PostPosted: Wed Jun 04, 2008 1:59 am 
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xc204, do they make these Clamp-On Tee's in smaller sizes, like 3/4"? If so I could see making a roof basket out of them and some of the other Structural fittings.

** Never mind, after some quick number crunching, it would cost way more to use these then to just buy one........ Oh well...... on to the next idea!!

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PostPosted: Thu Jul 10, 2008 4:04 pm 
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wow...... not bad at all for 30 bucks

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 Post subject:
PostPosted: Mon Aug 04, 2008 3:00 am 
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I think I am going to use these as a starting point for my fuel can mounts since I am getting rid of my roof rack.

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PostPosted: Mon Aug 04, 2008 11:26 am 
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Looks great! I too may have to borrow this design. Over the weekend I discovered that I am in need of extra trail needed items, lol.

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 Post subject:
PostPosted: Mon Aug 04, 2008 3:21 pm 
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Great idea! Definitely going to "borrow" this idea! Only problem is I don't go to Harbor Freight very often, about 25 minutes away. This one goes on the top of my to-do list. :D Gonna needs some Hella's sooner than I thought.

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Currently working on: Full service on transmission & bed-lining ARB bumper

viewtopic.php?f=43&t=84650


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PostPosted: Mon Aug 04, 2008 8:33 pm 
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I picked up six of the clamps from the web site. 2.99 each + 7.99 shipping. It was way cheaper to have them ship them to me then for me to drive the 45 miles (each way) to pick them up. Now I just need the top rail and a bender.

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245/75-16 Duratracs, Soft 8's, Ironman/clevis Lift, Monroe Sensa-trac rear shocks, JBA 3.5, GTP Hood Louvers, Roof Basket & Light bar, Mudd's Garage Rear Bumper
custom made items: cross rails, grill inserts, cargo shelf, lightbar, pin stripping & rock rails.
L.O.S.T. #DW090501


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 Post subject:
PostPosted: Mon Aug 04, 2008 8:52 pm 
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501 wrote:
I picked up six of the clamps from the web site. 2.99 each + 7.99 shipping. It was way cheaper to have them ship them to me then for me to drive the 45 miles (each way) to pick them up. Now I just need the top rail and a bender.


What are you planning on doing with the bender and extra clamps??

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2002 Jeep KJ Sport 3.7L 4x4

245/75-16 Mastercraft Courser HSX, 16x7 Cragar, 2" OME MD Lift, ARB Bumper
AEM Brute Force Cold Air Intake, Flowmaster Super 44 Muffler

Currently working on: Full service on transmission & bed-lining ARB bumper

viewtopic.php?f=43&t=84650


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 Post subject:
PostPosted: Mon Aug 04, 2008 8:57 pm 
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jeepkj02 wrote:

What are you planning on doing with the bender and extra clamps??


After I get my roof basket install I thought I might try and make a light bar for in front of it using the 3rd set of clamps.


I need the bender to bend up the rails so it fits tight to the roof line.

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Blood Clot Red 03 Punisher Edition
245/75-16 Duratracs, Soft 8's, Ironman/clevis Lift, Monroe Sensa-trac rear shocks, JBA 3.5, GTP Hood Louvers, Roof Basket & Light bar, Mudd's Garage Rear Bumper
custom made items: cross rails, grill inserts, cargo shelf, lightbar, pin stripping & rock rails.
L.O.S.T. #DW090501


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 Post subject:
PostPosted: Tue Aug 05, 2008 7:16 pm 
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For the bender try and find a "sparkey" (electrician) that has a bender for 1" rigid conduit Chicago Bender is what some call them. I you cut your pipe beforhand I would think they would do it cheaply or free. Find a 4x4ing elect if you can or ask on this site if any one is near you.

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2000 XJ 2.5" lift 245-75R16 MT's on Moabs
2006 KJ sport rear Air Lift,Clevis lift, front hitch rec. point,Front and Trans skids,Really Nice Roof Bars!
3 Jeeps owned
Favorite Destination Gunnison Co.


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 Post subject:
PostPosted: Tue Aug 05, 2008 9:31 pm 
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Thanks, I'll check around the area here. I work for a engineer here and I'm hoping one of the local contractors that work on our projects will help me out.

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Blood Clot Red 03 Punisher Edition
245/75-16 Duratracs, Soft 8's, Ironman/clevis Lift, Monroe Sensa-trac rear shocks, JBA 3.5, GTP Hood Louvers, Roof Basket & Light bar, Mudd's Garage Rear Bumper
custom made items: cross rails, grill inserts, cargo shelf, lightbar, pin stripping & rock rails.
L.O.S.T. #DW090501


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 Post subject:
PostPosted: Sun Sep 14, 2008 7:04 am 
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what if you didn't bend the pipe, would it still clear the roof line?

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 Post subject:
PostPosted: Sun Sep 14, 2008 10:14 pm 
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It would be very close. I think about 1/2" clearance. Looks better with the bends it looks like it follows the roof lines better.

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2000 XJ 2.5" lift 245-75R16 MT's on Moabs
2006 KJ sport rear Air Lift,Clevis lift, front hitch rec. point,Front and Trans skids,Really Nice Roof Bars!
3 Jeeps owned
Favorite Destination Gunnison Co.


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 Post subject:
PostPosted: Sun Sep 14, 2008 10:44 pm 
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XC204 wrote:
It would be very close. I think about 1/2" clearance. Looks better with the bends it looks like it follows the roof lines better.


but why do you want it bent up in the middle? Roof baskets are flat, anything you haul is generally flat, mine are 1/2 inch from the roof and no problems and mine are lower than 99% out there.

Mine are by the way attached in the middle of the side rails, with 1/2 inch all thread running through gas pipe, very strong. Drilled a 1/2 inch hole right through the side rails and went from there. Have had 4 mounted Good years MTRs on Moabs up there and not one bend.

Not sure why everyone wants to complicate the whole process :shock: :shock: :shock:

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