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. |
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 I made mine
just wide enough to fit a 1.2m roof tent. |
 Here are the
front supports. |