Building A Roof Rack

Scar0 · **Posted:** Sat Mar 13, 2010 2:42 am

KJWildman wrote:

JEden8 wrote:

Thanks for the photos KJWildman! Looks really good!

Scar0 & KJWildman:

How did you guys bend your piping? Did you use a conduit bender or is there a better way to do this?

I just used a simple hand conduit bender

Great looking rack KJWildman! How/ what did you paint yours with? I can't get anything to stick to the Galvi.

Yep, hand held bender for me too. I also got it at Lowes. This was the most $ of the hole project.

My total cost was around $300 - 350 including; welding spools, build materials, stainless hardware, conduit bender, grinding wheels, sandpaper, primer and paint.

KJWildman · **Posted:** Sat Mar 13, 2010 3:20 am

Scar0 wrote:

KJWildman wrote:

JEden8 wrote:

Thanks for the photos KJWildman! Looks really good!

Scar0 & KJWildman:

How did you guys bend your piping? Did you use a conduit bender or is there a better way to do this?

I just used a simple hand conduit bender

Great looking rack KJWildman! How/ what did you paint yours with? I can't get anything to stick to the Galvi.

I'm lucky ? enough to work at an automotive E-Coat/Powdercoat and weld assembly plant (electrician/industrial machine repairman). Pretty much anything I want to fab gets dipped in an e-coat primer then powdercoated

lots of welders, spot welders and fab equipment at my disposal. :goink:

yeah, rubbin it in! :lol:

sorry!

Scar0 · **Posted:** Sat Mar 13, 2010 4:38 am

Well now

Where are you located? Can I visit??? LOL
I think that is the route I will have to go. My paint stays on for about a year and then I have to repaint it. I'm getting real tired of doing it. The nice thing is it does not rust. :lol:

As the saying goes... Do it right the first time.

JEden8 · **Posted:** Sat Mar 13, 2010 10:47 am

I'm just looking to rhino line it. Are there any problems with that sticking?

Scar0 · **Posted:** Sun Mar 14, 2010 4:23 am

JEden8 wrote:

I'm just looking to rhino line it. Are there any problems with that sticking?

I haven't tried anything like that yet. I would prefer a paint type of finish on mine so it is easier to slide a sheet of plywood, 2X4's, or other building materials up there.

JEden8 · **Posted:** Sun Mar 14, 2010 11:18 am

Got ya. Is there any advantage to having the cross bars welded onto the side bars? I'm thinking about making them adjustable unless it's important to have them welded on. I'm going to pick up some tubing today to do some testing.

Also, Scar0, what did you use for the height in between the two "loops"? I'm trying to get an idea of how much tubing I'm actually going to need.

JEden8 · **Posted:** Sun Mar 14, 2010 4:42 pm

Well I gave it a try today. Didn't turn out too good though. I think I'm just gonna get the dimensions and have someone make it for me. No biggie. I appreciate all the help though guys!

MtnLuvr · **Posted:** Sun Mar 14, 2010 8:54 pm

KJWildman and Scar0, do you know about how much your roof racks weigh :?:

Scar0 · **Posted:** Mon Mar 15, 2010 12:36 am

JEden8 wrote:

Got ya. Is there any advantage to having the cross bars welded onto the side bars? I'm thinking about making them adjustable unless it's important to have them welded on. I'm going to pick up some tubing today to do some testing.

Also, Scar0, what did you use for the height in between the two "loops"? I'm trying to get an idea of how much tubing I'm actually going to need.

I only have 1 upper cross bar to form the front of the basket. Everything is welded to help prevent flex and increase strength. You could add another adjustable cross bar...
The space between my "loops" is 1 1/2", which gives me almost 2 3/4" deep basket. I wanted it low profile.

JEden8 wrote:

Well I gave it a try today. Didn't turn out too good though. I think I'm just gonna get the dimensions and have someone make it for me. No biggie. I appreciate all the help though guys!

Bummer, What kind of welder are you using? I had to sand off all the Galvi where I was welding to get a good steady arc.

MtnLuvr wrote:

KJWildman and Scar0, do you know about how much your roof racks weigh :?:

I haven't weighed my rack. But I can pick it up by my self. It takes 2 people to get it on top of the rig, just because I don't want to scratch up my ride. If I was to guess, I'd say 80 to 100 Lbs. total, including the extra mounting plates and lights.

JEden8 · **Posted:** Mon Mar 15, 2010 11:57 am

I appreciate the info. I'll be adding that into the dimensions. I may go 1/2" taller or so. I was running into problems with the bending. I didn't even get to the welding part. HAHA The tubing kept buckling and bending flat with the conduit bender. My uncle owns a welding company back in MI so I'm going to go through him. I just have to wait till July, the next time I'm back up there from FL, to get them. I'm also going to get the sliders made by him as well. I just need to get the dimensions for both the roof rack done and the sliders so he can have them made for me by the time I get up there.

Boiler · **Posted:** Mon Mar 15, 2010 4:35 pm

JEden8 wrote:

I appreciate the info. I'll be adding that into the dimensions. I may go 1/2" taller or so. I was running into problems with the bending. I didn't even get to the welding part. HAHA The tubing kept buckling and bending flat with the conduit bender. My uncle owns a welding company back in MI so I'm going to go through him. I just have to wait till July, the next time I'm back up there from FL, to get them. I'm also going to get the sliders made by him as well. I just need to get the dimensions for both the roof rack done and the sliders so he can have them made for me by the time I get up there.

Yep, I too have seen my share of flattened bends on roof racks and such. Not pretty.

It is going to be VERY difficult for you to have someone make you sliders and a roof rack to dimensions and expect it to fit. You really need the vehicle on hand to build around. I bolted feet to my roof, welded structure between them all, then measured the structure. If you can get the feet nailed down and then figure out where the highest point in the middle is, you have a start.

10x easier to just build one right there on the jeep instead of trying to build one to dimensions.

JEden8 · **Posted:** Mon Mar 15, 2010 4:51 pm

Boiler wrote:

JEden8 wrote:

I appreciate the info. I'll be adding that into the dimensions. I may go 1/2" taller or so. I was running into problems with the bending. I didn't even get to the welding part. HAHA The tubing kept buckling and bending flat with the conduit bender. My uncle owns a welding company back in MI so I'm going to go through him. I just have to wait till July, the next time I'm back up there from FL, to get them. I'm also going to get the sliders made by him as well. I just need to get the dimensions for both the roof rack done and the sliders so he can have them made for me by the time I get up there.

Yep, I too have seen my share of flattened bends on roof racks and such. Not pretty.

It is going to be VERY difficult for you to have someone make you sliders and a roof rack to dimensions and expect it to fit. You really need the vehicle on hand to build around. I bolted feet to my roof, welded structure between them all, then measured the structure. If you can get the feet nailed down and then figure out where the highest point in the middle is, you have a start.

10x easier to just build one right there on the jeep instead of trying to build one to dimensions.

What if I were to make dimensions of a wooden structure (much like you use) and gave those dimensions to him for a guidance?

Boiler · **Posted:** Mon Mar 15, 2010 5:42 pm

You could try it.

BrendonR · **Posted:** Mon Mar 15, 2010 5:48 pm

i would assume it would 'work' but not well in my opinion.

It would seem to me that you'll spend a lot of time and money to get it right that way. How would you make sure you had all of the angles you wanted right? The simple fact that wood will be different sizes/shapes than the tube you want to use (unless you spend a lot of money on wooden dowels), to ME there would be WAY to high a chance that your Uncle will get a nice rack all welded up, then when you get to his place to mount it - uh oh, something's off.

Scar0 · **Posted:** Mon Mar 15, 2010 9:17 pm

I built the rack first according to the dimensions I wanted. Then I made the foot plates. I got some over-sized angle iron for the "legs". Measured and cut the angle iron to fit (between the rack and feet) with the rack on wood blocks on top of the rig. Then I welded the rack to the legs and legs to the feet, while it was all on the rig.

Either way could work (rack first then feet, or from the feet up), if your measurements are accurate.

But, you will not be able to weld the rack to the legs and the legs to the feet without having the rig on hand (too many complex angles).

I definitely agree with Boiler, It would be much, much easier with the rig on hand.

Boiler · **Posted:** Tue Mar 16, 2010 2:40 am

It is very difficult to get real, accurate, usable measurements off the roof. All of the mounting pads are on different planes. I'd strongly advice to build it to fit or don't build it. It can be done, as I did it, but the way I did it was to measure it exact, design it exact, build a fixture as accurately as we could with drills and saws, and then build the parts as accurately as possible. We made our jig to match the CAD models and attempted to get everything within maybe 0.010". The parts, though they varied, were held in an accurate manner each time.

Without going through great lengths, measurements won't mean much by the time the rack is built.

Now, you might be able to measure up a rack design WITHOUT including an interface to the roof, and then build the feet / attachment legs at the time of install.

Scar0 · **Posted:** Tue Mar 16, 2010 6:23 am

Boiler wrote:

Now, you might be able to measure up a rack design WITHOUT including an interface to the roof, and then build the feet / attachment legs at the time of install.

Thanks Boiler that is what I was trying to say. You just did it much more eloquently.
That is exactly what I did.

JEden8 · **Posted:** Tue Mar 16, 2010 6:43 am

Boiler wrote:

It is very difficult to get real, accurate, usable measurements off the roof. All of the mounting pads are on different planes. I'd strongly advice to build it to fit or don't build it. It can be done, as I did it, but the way I did it was to measure it exact, design it exact, build a fixture as accurately as we could with drills and saws, and then build the parts as accurately as possible. We made our jig to match the CAD models and attempted to get everything within maybe 0.010". The parts, though they varied, were held in an accurate manner each time.

Without going through great lengths, measurements won't mean much by the time the rack is built.

Now, you might be able to measure up a rack design WITHOUT including an interface to the roof, and then build the feet / attachment legs at the time of install.

After hearing both of your guys input, I think what I'm going to do is just get him the measurements of everything for an estimate. Then have him have everything cut so that when I'm home we can then weld it together on it itself. Just have him cut everything a little longer for fix actions and we can take it back once needed. The problem I'm running into is I'm only going to be home a week. This is why I posted this is so that I make sure I do everything the correct way. You guys know what you're doing and I appreciate all the input!

Scar0 · **Posted:** Tue Mar 16, 2010 9:22 am

Remember the Pics, or it never happened... :-)r

BrendonR · **Posted:** Tue Mar 16, 2010 11:26 am

JEden8 wrote:

After hearing both of your guys input, I think what I'm going to do is just get him the measurements of everything for an estimate. Then have him have everything cut so that when I'm home we can then weld it together on it itself. Just have him cut everything a little longer for fix actions and we can take it back once needed. The problem I'm running into is I'm only going to be home a week. This is why I posted this is so that I make sure I do everything the correct way. You guys know what you're doing and I appreciate all the input!

My plan for a roof rack is coming together actually as well - so definitely post pics of yours.

What I was planning was to make side-rails similar to those that Rocky Road produces: http://www.rocky-road.com/kjrails.html

Those will be made with the vehicle on hand/on the vehicle - for my use, i need to remember to make them parallel to the ground, not the roofline - which I think is higher at the front than the back

I was also planning on making a basket - ideally something similar to the Nitro Gobi Basket: http://www.gobidodge.com/nitro.htm - low profile and still functional.

This could be made on, or off the vehicle - depending how you want to mount it. I was planning on using a u-bolt clamping system TO the above rails, which would mean that I could make it without too much 'on vehicle' work.

So, if you wanted to save time with your Uncle - have him make you up a basket, to the dimensions you want - and when you get there, work on siderails / mounting system to your roof.

Building A Roof Rack

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