Building A Roof Rack

Boiler · **Posted:** Tue Mar 16, 2010 2:34 pm

BrendonR wrote:

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

What is your use that requires them parallel to the world? Unless you're interfacing the ground with some attachment or using it as a tent platform, I would do this:

1) remove existing rails
2) Place a 1/2" thick piece of wood on the roof, laying across the middle two ribs, in the approximate the center of the four mounting pads.
3) place a 4x8 sheet of 1/2" plywood on the roof. It should be bacially centered teetering on the 1/2" piece of wood from #2.
4) At the center point between each pair of bolt holes, build up vertically to support the sheet. Make all four corner supports the same length.
5) Once you have all 4 corners even, run a straight edge across the wood and make sure it is flat. If it is not, adjust the 4 corner lengths equally to make it flat.

What this will do is give you a rack that looks like it matches the slope of the jeeps roof. With common lifts (22-23" front, 22 to 22-1/2" rear) it will look relatively level with the world. It will definitely look balanced with the top of the jeep.

If you're going full length, do the same process but instead of using the front pads, build up from a point at the front end of the proposed rack, and scoot the center support forward.

Note: I'd recommend not going any closer than 1/2" from any rib on the roof. Any closer and it will be even worse to wax, and you run the risk of knocking on the roof when loaded / flexed / hitting bump in the road. You definitely want some stiff tubing if you go that close or closer.

BrendonR · **Posted:** Tue Mar 16, 2010 3:01 pm

Thanks for the input Boiler - you are certainly the man when it comes to racks here.

it was only an initial assumption, however, my thought was with a full - or almost full length basket, keeping it with the roof line would allow more air trapped between the roof an the basket.

I suppose however, with the basket not actually being solid bottomed, it wouldn't really matter much would it? I do admit, it would look better to be with the roofline rather than the world.

Boiler · **Posted:** Tue Mar 16, 2010 5:08 pm

BrendonR wrote:

Thanks for the input Boiler - you are certainly the man when it comes to racks here.

it was only an initial assumption, however, my thought was with a full - or almost full length basket, keeping it with the roof line would allow more air trapped between the roof an the basket.

I suppose however, with the basket not actually being solid bottomed, it wouldn't really matter much would it? I do admit, it would look better to be with the roofline rather than the world.

If you're worried about airflow, I wouldn't, unless like you say, it has a solid bottom. Also, lining up with the world all depends on your lift.

Scar0 · **Posted:** Wed Mar 17, 2010 1:39 am

BrendonR wrote:

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.

My secret is out... I designed my rack similar to the Gobi one. At $1.350 I felt it was WAY out there cost wise. I also liked the low profile of it.
I basically did as Boiler pointed out above to make the legs, once I had the rack built.
I'm far from being a Pro fabricator.
So again, Thanks Boiler for your invaluable input in this thread!

Building A Roof Rack

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