Hey guys thought I'd share my idea I came up with making some cross bars for the base of my roof rack ill be making soon. Anyway I used a square piece of aluminum and 4 ubolts drilled holes for the ubolts and painted it black. Next I am going to build a cargo basket that I will weld to cross bars so the whole unit can be removed. Here's a couple pics.

_________________
2006 Liberty KJ
- 3.7 V6 - OME 927/948 - Bilstein shocks - Teraflex bumpstops
- 245/75/16 Hankook Dynapro ATM - 1.25" Spidertrax Wheel Spacers
- Boiler's Roof Rack - CRS Rock Rails - All J Cargo Tray
- Cobra 75WSXT - 4 LED Roof Lights - Bed Lined Bumpers/Fenders

Thats a good start.
The piece that comes with U bolts is thin you might want to make a stronger piece out if thicker steel. Id use some 1 inch and drill 2 holes.

Yea I agree those metal pieces that come with the u bolts arnt very strong they were bending when I tightened it down but it feels like its on there strong I yanked it pretty good and it didn't budge. I like your idea of thicker steel will probable upgrade to that when I get the rack done. Need to plug the ends with something too as it has a little howl I noticed driving to work this morning.

_________________
2006 Liberty KJ
- 3.7 V6 - OME 927/948 - Bilstein shocks - Teraflex bumpstops
- 245/75/16 Hankook Dynapro ATM - 1.25" Spidertrax Wheel Spacers
- Boiler's Roof Rack - CRS Rock Rails - All J Cargo Tray
- Cobra 75WSXT - 4 LED Roof Lights - Bed Lined Bumpers/Fenders

Yes you will get some noise. Yours are low so it shouldn't be bad.

why not flip the u-bolt over?

_________________
02 KJ Limited, 255 70 16 General AT2, Ironman Lift, JCR sliders, Mopar skids, radiator skid, LS/373 gearing, factory front hooks and rear hitch

92 XJ 4.0, AW4, NP242, 31s, 1.75 spacer, ZJ V8 coils, double cherokee leaf pack, 2 inch shackles, dnynomax exhaust, magnaflow cat, front hooks & rear hitch, gas tank skid, front skid, warn t-case skid

Started mine the same way.

2 inch square tubing, some careful measuring for roof rail centers, and a little creativity.
Lined up my centerlines, C clamped a piece of 3/4 inch plywood between the crossbars, and used
a 1 3/4 inch hole saw to make notches for the roof rails.



Drilled the crossbars for 1/4 X 20 bolts, made the clamps by bending 2 inch 16 gauge strips around a shovel handle.

A little rattle can black after priming, and they're solid as a rock



Add a basket, and PRESTO!!!



A grand total of about $60 in materials, including primer and paint, and a few hours of my time.

_________________
Brad
International Man of Mystery, Singer of Sentimental Ballads,
Soldier of Fortune, Guardian of the Holy Hand Grenade of Antioch,
Bass Player Extraordinaire, Keeper of the Eternal Flame
of the Immortals, Master Swordsman, The "5th" Beatle,
Expert Marksman, Stand-up Comedian, Martial Artist,
Jeep owner, and all around swell guy.

I didn't want to flip the u bolts over cuz I didn't like the way it looked. Plus the way they are set up now it provides a tie down point to secure a load on top. I think it's crazy there is racks out there that are $400 and up when you can make one for under 100. Like the idea above too very clean!

_________________
2006 Liberty KJ
- 3.7 V6 - OME 927/948 - Bilstein shocks - Teraflex bumpstops
- 245/75/16 Hankook Dynapro ATM - 1.25" Spidertrax Wheel Spacers
- Boiler's Roof Rack - CRS Rock Rails - All J Cargo Tray
- Cobra 75WSXT - 4 LED Roof Lights - Bed Lined Bumpers/Fenders

i like that light bar too!

_________________
2003/3.7 SOLD

2007 Wrangler - traded

2010 Wrangler Rubicon