CBR (Cruiser Built Rack) Prototype Upfit and Install

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LCAdvocate

LCAdvocate

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New Roof Rack Prototype Upfit and Install

This is a prototype off-road rack that I designed and fabricated for the 100 series Land Cruiser. It is a prototype and no where near perfect, but the idea is evident. The idea and design was conceived to offer some features that spanned the products currently available on the market. Specifically, the rack needed to be light(er), rust proof or rust resistant, offer integrated wiring and power points, match the vehicles lines and angles, work dimensionally with LED lights, reduce wind noise, and of course be very strong. I am still working on fine tuning the rack and outfitting it with the light package. I am open to ideas for future features, changes and possible accessories. The shadows are playing with some of the angles in the pictures and the Dually on the rear is not completely mounted yet - I have misplaced part of the mount and had to order another. Here are some of the technical details:

- 6061-T6 all aluminum construction - ultimate tensile strength of at least 42,000 psi and yield strength of at least 35,000 psi. Retreated after welding.
- Mandrel bent radii
- Main rails are 1.5" OD with 1/8" walls
- Rack is 47"x78" overall and clears the high point of the roof by about 1"
- Top rail is 9" from bottom of roof mount
- Top of 40" LED is approximately 12" tall
- Basket area is 41"x48"
- Top rail width is 43.5" and bottom rail is 47"
- 1.5" tubing allows the use of market available mounting systems such as Axia Alloys, All-Pro Off-road
- Future racks will have an integrated mounting rail also
- Floor system is 1/4" flat bar stock with 1/4" cross bracing
- Upper edges of floor members are rounded over
- Main floor members run front to back, with the wind, not across
- Integrated fairing with concealed fasteners
- Grab bar for standing in sunroof and access to rack contents
- Tubing serves as raceway for wiring and exits tubing with a inline disconnect for rack removal (still working on this part)
- Integrated mounting points (5) for power plugs/receptacles
- Hella waterproof marine grade screw down plugs/receptacles with rubber gaskets at mounting points
- Silicone electrical wires, shrink wrapped at connections, enclosed in flex tubing and shrink wrapped again
- Mirrored angles: Fairing, upper grab rail portion mirror windshield angle; upper and lower side rails mirror side glass angle, rear upper and lower rails match rear window angle
- Design incorporates 5 Rigid LED's - 40" E, 2 - Dually's and 2 - Mini's
- Top rail width perfectly accommodates a 40" Rigid LED bar light
- Between rail height accommodates the Rigid Mini and Dually lights while the upper rail being inset from the lower rail protects the lights from the contents
- Six roof mounting legs with 1/4" EPDM gaskets and 6061 spacer blocks - require removal of metal roof channel
- Load test performed to 500 pounds with minimal floor deflection
- Aluminum and stainless steel bolts and hardware, except for Hella plugs which are chrome plated brass
- Galvanic reactions are kept to a minimum by use of EPDM buffer between Al and metal roof, and rubber gasket between Hella plugs and mounting points

I will be installing it this weekend hopefully and posting more pictures.

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I like it. Part gobi, part stock FJC. not bad looking at all
 
cool , looking forward to seeing it mounted.
 
Looks great. I would agree that ability to incorporate an RTT would be essential. Although 'folding the light out of the way' would render it useless for an RTT. It's not like you mount the RTT once you get out there.
 
couldn't the led bar be mounted in front of the fairing?
 
Looks great I like the ideas incorporated. Glad to see you went forward with this. So will you be marketing this?
 
I would suggest that you look at some type of a removable/sliding front basket that transforms it from a full rack to a rear rack. Having the clear space in the front for the sunroof is a nice feature but not at the expense of limiting full utilization. Not that many owners are spending $$$ on a nice rack anyway, and certainly not for both kinds. A transforming rack would make you unique and more relevant in the market. Users could have the option of 'bikini' mode for day tripping and a full rack for expo.
 
BamaHeel said:
Looks great I like the ideas incorporated. Glad to see you went forward with this. So will you be marketing this?
Click to expand...

I am definitely thinking about it. Completely depends on interest. As you know, the prototype cost is high, so I would need to get a few people interested to get the cost down. I have already spoken to Rigid concerning a package deal on the lights with the customer being able to select specific models.


OregonLC said:
I would suggest that you look at some type of a removable/sliding front basket that transforms it from a full rack to a rear rack. Having the clear space in the front for the sunroof is a nice feature but not at the expense of limiting full utilization. Not that many owners are spending $$$ on a nice rack anyway, and certainly not for both kinds. A transforming rack would make you unique and more relevant in the market. Users could have the option of 'bikini' mode for day tripping and a full rack for expo.
Click to expand...

That was actually part of the original design, but due to a fabrication boo boo I had to abandon that idea with the first rack. The rack should actually be a bit longer at the grab bar section, which would allow for roughly a 18"x40" removable basket. Sliding is a good idea. I'll work on that.
 
I would put the light in the roof rack and not ontop. It will get old every time you pull into a garage and find out you are a little too tall. The light bar isn't necessary all the time, so make it invisible when it comes to day to day operation. There is no point in your fairing, the light bar is going to generate a huge amount of wind.
 
2000UZJ said:
I would put the light in the roof rack and not ontop. It will get old every time you pull into a garage and find out you are a little too tall. The light bar isn't necessary all the time, so make it invisible when it comes to day to day operation. There is no point in your fairing, the light bar is going to generate a huge amount of wind.
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The Axia mounts and Hella disconnects allow for the light to be removed quickly. The lower portion of the fairing is forward of the light and there is a channel (gap) between the light and the fairing, which will allow the air to flow over the basket contents. The purpose of the fairing is to help divert air over anything in the rack and the light needs to be up top or else quite a bit of light will be directed onto the roof and hood. I'll verify this when I get it mounted, but that was my original thought behind this design and layout. The light would probably fit in between the upper and lower rails either forward or rearward of the fairing if removed, but forward would interfere with the removable basket and both positions might waste some of the available light.

It fits in my garage with the light mounted. I know it will not fit in most garages, which is another reason for the quick disconnects. Two nuts, one screw cap bolt, one screw down power plug and the light is off.
 
I concur with 2000's comments...

Above all, I salute your efforts on this, considering that it's a first prototype, it's very impressive. I don't have the money for it just yet, but I'm on the market for a rack eventually and I'd be lying if I said that ANY of the products were compelling to me right now. Lots of good product, just none that have completely won me over as of yet. I have a feeling that if you had the money for 3-4 prototypes, you'd be able to refine your design to capture some real market share. That's the hard part isn't it?? You're off to a great start...I wouldn't give up..

Like:

I like the distance between the top and bottom bars. If you're going to be build a rack, it's redundant to have them close. I get the appeal of the flat racks, but the MOST important piece of functionality is the ability to safely store my belongings and prevent them from meeting the roadway in any form. My plan is to stuff surplus, waterproof military duffel bags onto a rack and simply tie them down.

Not Like:

My biggest challenge is the rack covering the sunroof. Personally, I don't care if it's covered. I'm in Texas, we get all the sun we need. If the rack covers the sunroof, big deal. I would jump on your rack if it were longer. I'm indifferent to the lights at this point, BUT I want that option for later, so I think the ease in removing a light bar is smart.

My suggestions:

Make the rack longer overall and address some method of making it operable with a sunroof. Buyers like me are indifferent to it being covered. I didn't buy an LC for a sunroof, but I'm sure there are others that simply want the space uncovered, so have the rack go over it without blocking it and you should be good.

I think there is a LOT of room for all the products to grow in terms of aesthetics. Too many look like weekend exercises. I honestly believe you can design a sleek, simple product without spending piles of money, but it's just gonna take try and retry.

That being said, what I wouldn't do is simply put a piece of flat metal between the bars to deflect wind on the front. I've never seen that look good.

Good luck on this, and don't give up, I think there is plenty of room in the market for a rack that's functional and has a certain aesthetic appeal, you've just got to stick with it til you find it.

Great start and good luck!
 
El Cid said:
I concur with 2000's comments...

Above all, I salute your efforts on this, considering that it's a first prototype, it's very impressive. I don't have the money for it just yet, but I'm on the market for a rack eventually and I'd be lying if I said that ANY of the products were compelling to me right now. Lots of good product, just none that have completely won me over as of yet. I have a feeling that if you had the money for 3-4 prototypes, you'd be able to refine your design to capture some real market share. That's the hard part isn't it?? You're off to a great start...I wouldn't give up..

***Thank you for your comments and advice. The next rack would definitely be cheaper to build and there really weren't any issues with this one other than the front being shorter than originally designed, which meant the basket couldn't be built and used.

Like:

I like the distance between the top and bottom bars. If you're going to be build a rack, it's redundant to have them close. I get the appeal of the flat racks, but the MOST important piece of functionality is the ability to safely store my belongings and prevent them from meeting the roadway in any form. My plan is to stuff surplus, waterproof military duffel bags onto a rack and simply tie them down.

***Yes, a rack should hold stuff securely. That was the first thing I wanted in the rack. I wanted to fill it with wood, gear, tires if necessary and have it hold those securely. There are plenty of platform racks on the market already. I didn't want another place for an air mattress:lol:

Not Like:

My biggest challenge is the rack covering the sunroof. Personally, I don't care if it's covered. I'm in Texas, we get all the sun we need. If the rack covers the sunroof, big deal. I would jump on your rack if it were longer. I'm indifferent to the lights at this point, BUT I want that option for later, so I think the ease in removing a light bar is smart.

***It does not cover the sunroof. The grab bar section should be at least 6" longer (7' overall length) and would accommodate the removable basket section. In an earlier thread, I talked about the fabrication problem that lead to the rack being shorter.

My suggestions:

Make the rack longer overall and address some method of making it operable with a sunroof. Buyers like me are indifferent to it being covered. I didn't buy an LC for a sunroof, but I'm sure there are others that simply want the space uncovered, so have the rack go over it without blocking it and you should be good.

I think there is a LOT of room for all the products to grow in terms of aesthetics. Too many look like weekend exercises. I honestly believe you can design a sleek, simple product without spending piles of money, but it's just gonna take try and retry.

That being said, what I wouldn't do is simply put a piece of flat metal between the bars to deflect wind on the front. I've never seen that look good.

***I'd like to think that it is more than just a flat piece of metal. It is sculpted around the upper and lower side rails and has nice bends in between the upper and lower rails so air will flow around it easier.

Good luck on this, and don't give up, I think there is plenty of room in the market for a rack that's functional and has a certain aesthetic appeal, you've just got to stick with it til you find it.

Great start and good luck!

***If I ever get my rig back from the gear shop, then I will install this thing and finish it up. Thanks again for your input.
Click to expand...
 
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