Fabricating a Custom Roof Rack

    It was time to tackle a roof rack.  I really wanted one so I could carry all my gear and still have room in the back for my son or my dogs.  I don't care for the Safety Devices or Urban Offroad racks as I think they look like giant shopping baskets.  They are also poorly made with pinch welds and utilize weak mounting points on the aluminum body.  Those two rack designs also require modification to mount roof top tents.  So I came up with my own design - open in the front so I could fit a 1.2m tent - and much more stout in terms of welds and mounting.  I sourced 1 1/2" steel tube and 1" steel box and used stainless or grade 8 hardware where needed.  For the two front support bars, I went to Rock Hard 4x4 for some 1 3/4" fabrication collars.  Total cost in materials was about $300, but I did get a smokin' deal on the steel.  As for labor, it was a kick in the balls - a full 3 1/2 days of labor, or about 30 hours of fab time.

I started with the bottom hoop of the basket.  Making two matching hoops requires careful measurement.  Once done, I check for square and weld them together to form a rectangle.

Next, I weld in the floor supports.  I added a little more than required so I could carry gear without adding a mesh floor if needed.

Next, I bent up the top bar of the basket.  This was a simple hoop with the ends turned down.

Here is the top hoop test fitted with the vertical supports.  You can start to see the final look of it.

Now it was time to start the more difficult part of the project - fabricating the rear ladder assembly.

This took careful measurement and a lot of trial and error.  I bent a hoop with the ends flared out 25 degrees to match the outside edges of the hard top, then bent it in at the top .

The inner part of the ladder is a separate piece of tubing and gets the same bends.

Here is the rack test fitted.

The final rear ladder assembly.  On the passenger side I used the tire carrier mount as a mounting point, and on the drivers side I tied the ladder to the rear crossmember.  There is also a support that mounts to the license plate factory holes.

After some paint it's starting to come together.

I added an old Con-Fer axe and shovel mount to the side of the basket.

And mounted my Hi-Lift jack on the back.

Here is the ladder mount on the rear crossmember.  I think this is where the Safety Devices and Urban Offroad racks fail.  They mount their racks to the thin aluminum body.  My mount doesn't stick out any further than the rear bumper and provides a stout mounting point.

The front roll bar mounts utilize Rock Hard 1 3/4" fabrication collars.

The final front support design.

And voila!  All done.  All the look of the expensive Safety Devices or Urban Offroad racks for a fraction of the price.  Plus mine looks better and is more functional.

Here you can see my rear crossmember mount.

I made mine just wide enough to fit a 1.2m roof tent.

Here are the front supports.