Building A Roofrack

CarmMontana · 10-13-09, 07:54 PM

Hey Pig Lovers.

I 've been taking a fabrication class and started making a roof rack for my Pig. I figured I would show you the progress and ask a question or two.

*Pictures are from start to where I am currently, sorry I didn't take any pictures of me bending the tube.

* Question: Should I weld in one more crossmember, i have the two. Not sure how much weight the two crossmembers can hold. The rack is 4 ft by 84 inches. I used 1" .065 tube so it isn't to heavy.

CarmMontana · 10-13-09, 07:58 PM

pic 1: The towers I built
pic 2: A side view
pic 3: My ghetto press, works well!

tag3 · 10-13-09, 08:50 PM

The more crossmembers the more distribution of weight.

fjdaveinoz · 10-14-09, 12:36 AM

Looking good
I used to work for a major aussie roofrack manufacturer for a number of years, if you need some ideas let me know.

What tag 3 said is correct - the more crossmembers the better the weight distribution. The gutters on these are only rated to 100kgs spread over 3 crossbars. I have seen people load them with a lot more, but 100kg is where the line in the sand is drawn.

Good Luck
Dave

hicruise55 · 10-14-09, 07:03 AM

Looks good! Nice welds too!

For the mounts are you going to make them clamping or weld them? When I do mine, I'm gona make the rail mounts a little longer(4" or more) just to spread the load and clamping force, my Con-fer now will bend the raingutters if tight, and rattle loose in a week if NOT "tight"(maybe locktite? but I like to remove it as it holds my RTT) I will then use the plasti-cote to give a little cusioning between metals...? Just some thoughts? Aaron

CarmMontana · 10-14-09, 07:27 AM

Hey Aaron

Thanks for the comments.

For the mounts i am going to clamp them, I welded a bolt thru the towers and formed the clamps last night. I am hoping the system will work well, kinda just taking a shot in the dark. I did the rail mounts at 3" because that is all the room I had, made my rack wide enough to fit plywood, at least in width. I also tapped the rail mounts and put in a cap screw so the mounts can be tightened to the rack.

The plasti-cote idea is something i have been thinking about. Do you think it would hold up after some time? I also have some rubber that I may try and put on there. Not sure yet

toddslater · 10-14-09, 03:04 PM

Looks very familiar....although I did mine out of illumnum cuz I'm a

and weak

I opted to use heavy gutter mounts. Been working fine for 7-8 years now. Good luck with yours and it is looking good

CarmMontana · 10-14-09, 06:45 PM

Nice, You kidding me. If I had a Tig I would have done aluminum for sure. Looks great.

Found some expanded metal in my steel suppliers recycling bin, we'll see what i do with it. Maybe on the corners? What do you guys think?

Lil'John · 10-14-09, 09:18 PM

I'd go with more "longer" gutter mounts.

Once I get around to doing a rack for my 55, I'll go with a total of eight mounts to the gutter(four a side).

I plan to have the gutter mounts be as "wide" as the gutter(3/4"??) and three inches long.

This should distribute the load better.

I'm still debating the overall look but I plan to have no floor in it. I will use a piece of plywood when I need it.

I've thought about your type: aka the standard roof rack look. But I've also thought something more "half pipe" look with the front and back open but "easily" closeable.

My intended us is camping garbage up there but also the ability to haul long lengths of lumber... need something since my truck is going out the door

fjdaveinoz · 10-15-09, 05:17 AM

Have you thought about using small square mesh for the base? It allows the air to pass through it when not loaded, isn't heavy, and allows you to have an infinante amount of tie down points throughout the floor of the rack. Good for strapping down a tyre, or small odd objects.
We also found powder coating gives a long lasting durable finish. The plasti cote finish (at least the ones we tried) cracked after a while and peeled, and doing a up a rope on it would sometimes burn through it. You may have access to better products there though.

Looks like your doing a top job.

Dave

CarmMontana · 10-15-09, 08:12 AM

So I took some advice on the towers I built and decided to widen them a bit. I will make one more crossmember and two more towers also. That should give me enough weight distribution. So plywood verses expanded metal, not sure which one I will pick. I need to go price the metal and see what will be the best option. The infinite tie down thing is very appealing though.

Thanks for all the comments guys. I am trying to make it as pro as is possible in my little shop and it is turning out better than I expected.

Pic 1: pic of the towers after a little brainstorming about the base. I stiched welded theese so that I can grind them down flat. How do you like that gash in my hand, grinders can really get ya!

Let me know what you think.

Pic 2: The expanded metal I am thinking about placing on the radius' of each bend on the rack. Any Pros or Cons there?