Hi, you have me very intrigued about your roof rack. I watched the video, downloaded the plans, but was interested in what dimensions you used for your rack? What did you use for the gutter mounts? I might have to go this route!
Hey man! Sorry for the late reply. I'll try to provide as much detail as possible. All of these dollar values are pretax and shipment.
As far as the roof rack mounts I went with Dirt Dog Offroads heep mounts. $80
UNIVERSAL GUTTER ROOF RACK MOUNT WELD ON XJ ROOFRACK GUTTER MOUNT FLAT FULLWIDTH SET OF 8 | Dirt Dogs Offroad
For the crossmember I went with the Tnutz ones outlined in the video. I went with 10 but you can use however many you need. I personally believe distribution of weight is of utmost importance on a gutter style roof since those are very prone to rust. I went with 54 1/4 inch wide as that allowed the roof rack mounts to stand straight and distribute weight only in the down direction and not laterally. I also had the holes pretapped. It cost me $241
EX-1020-BLACK – 1″ x 2″ BLACK Smooth T-Slotted Aluminum Extrusion | TNUTZ | TNUTZ
For the sides I used 3/16 x 3in x 8ft (Width,H,L) long flat stock. It cost me $80 at Reno Salvage in Reno, Nevada.
For the wind deflector I went with 3/16 x 6in x 5ft (Width,H,L) flat stock. I dont remember exactly how much it was but was around $80.
As for the bolts I went with T30 Black Zinc Plated steel bolts. I ordered two sets which was like $30.
bolts
Washers...
Washer ~$8
Lock Washers ~$4 x 3
The nuts I already had which I purchased from Harrison & Bonini in San Francisco. Lets say $20 MAX.
The powdercoating was done by a local shop in SF. It cost me $170
Total cost estimate: ~$713. This will vary depending on where you source your aluminum but I find it to be FAR more customizable and cost effective than other comparable (functionally) alternatives.
As far as dimensions and cuts I really just played it by ear. I tried to follow the body lines of the truck. I cut and drilled both side pieces clamped together. As for the front wind deflector I had to wing that as well. I mocked one up out of cardboard first and then traced it on the aluminum piece cut with a cutting wheel. For the long cut, DON'T cut deep right away. I basically made a track which I followed back and forth until the piece was cut. Then I very carefully worked on any imperfections with a sanding wheel. It didn't turn out "perfect" but it's close enough and you'd never know unless you were looking for it. I don't remember the angle I based the wind deflector on but it was around 40 degrees IIRC.
Let me know if you have any more questions!
