LC100 series roof platform out of 80-20 extrusions, very slim..

[Patineto]

Sorry it i post this before, not sure.

I'm not even close to be done with this one...

Is made of 80-20 extrusion profiles, longitudinal beams "3015" (3"x1.5") and the two main stiffener one in the front one at the back of "3030 (3" by 3" massive chunks)

Basic lay out, 4" extending over the back (form a extended platform).

My main issues where..

The discrepancy in how wide the roof of polar bear is. (1 1/16") total)

Measure it a few times with my own "Caliper" (all the results where repitable)

Actually today I have some progress..

Let me tell you this 80-20 stuff is a dream to work with (they are a few imitators some of them with even better features

I love the adjustable, is just so flexible a few minute and you can be really to carry something very specific..

this is my current interpretations, remember I got the material used so some of the lengths where already preset (the longitudinal beams for example.

Working in-Situ and in the snow is kind of a pain (my driveway is super step, everything tends to roll and slide.

I also love to use recycle, purpose materials, for example the upper pieces are from my old motorcycle company (KTM 950 GPS/whatever mounting for the handlebar) (they cost crazy money to make but it was a market interpretation mistake)

The lower part is a lower triple clamp from a KTM 65cc (I have tons of friends in the industry (Sadly I only have 9 it will be perfect to have Ten) obviously the steering stem will be modified (I need to head them up, extract the steer tube and reattach the last 65mm) I don't think I have picture of the ensemble but all the parts are ready.(mostly turn delrin "Coins"

Everything is made to "Float" so some flex of the interface, but is also extremely stable as a platform.

Sorry mosquito netting at the windows, hopefully tomorrow I will have some more..

The whole "Base/foundation" is made to spread the load OVER the whole surface of the roof, I love Riv-nuts but I also understand their limitations, so I want to prevent them from pooping out and damage the "Rail mounts"

Here are all the pictures I have collect on the 80-20 but they are thousands over the internet, this system change the "Working prototype" industry in days, is just very pragmatic and adjustable to wonder a great majority of the DIY CNC machine are made of it.
80-20 roof platform

So much more to come, front air control management via a "Hack" Wakeboard with variable angle property, also the back side is going to be very funky but with a lot of potential for flexibility..

Most parts are from my fail Rcikybar company, motorcycle parts that where not suitable for, tons of repeatable parts that i just got lucky to find, most simple pieces (Made out of the same recycle chuck of delrin "pucks" (thanks JP Morgen) modified with my Unimat latte that serve a bunch of different functions..

I will post as the progress happen..

 

[Patineto]

This Lego like structures are so easy to build and so very sturdy, besides the high cost (They are cheaper (the same or less sophisticated, less features) imitation and/or build of different alloys) it will be such a easy way to send out a kit to be ensemble by the end users, total Ikea, but a IKEA that those not bend or break even on the most insane conditions, plus is absolutely modular)

This is not about money but I calculate the main structure is going to end up costing about a 1/3 of the best rack I can find (in my opinion).. but remember I also has a bunch of custom made parts already (some purchase for super cheap, some impossible to repeat or at least cost prohibited..

The only part I don't like is that if you forget a nut (special rectangular steel with threads) in the middle of the extrusion is a total pain in the bumbumm to get one in.

I was even tempted to drill a hole every two feet or so to make nut insertions much easier..

 

[Patineto]

1. Is a shame is so snowy, makes it kind of impossible to work on the truck (surface are so slippery) but I think I'm done with all the parts the rack require, now locating and aligning the rail with the platform is the really difficult step..

 

[Patineto]

So far i'm very happy with the results, is coming along pretty nicely, just some advice don't work with small black fasteners in the snow, what a pains, besides slippery it becomes mud in no time when you spend some time working on the same area..

This is a extension for the rear, made of four motorcycle triple clamps and Hanglider wing tubes.

I still need to cut the second farther back tube, but the structure will fold on his own when no in use..

Is going to serve as a "Ladder" for my girls (they love mini rock climbing..)

This are the side fences that will also work as a "rotating bike rack" (will rotate 45 deggres or so, load the bike up and then bring it back to vertical (The beauty of hydro pistons..)

The D-ring rail need to be more one facet counterclockwise, no big deal three minute job, man I love this stuff.

Now I need to wait for a friend to come and help me, this extrusions are very rigid because besides the 6061 they are really thick wall and very sound in terms of "Internal triangulation"

Enjoy, more coming when the sun comes out..

 

[Patineto]

Just in case somebody is interested on a DIY project, in my mind this is the ideal extrusion for longitudinal members..

Great support for the traverse bars.
80/20 EXTRUDED ALUMINUM L-SHAPED PROFILE 40mm X 80mm X 40mm X 2100mm 82.68"LONG | eBay

 

[Patineto]

I think I'm done in terms of structure, if anything is to stiff..


here is a set of the 8 connectors for the roof.

The second from the closes (Back side at the bottom of the picture are 3" by 1.5" that way the rigidity is certain and the rest of the beams are 1.5"x1.5" for clearance with the ceiling of the truck.

This is one of the pivots for the motorcycle triple clamp..

No i just need to wait for two friends to come for some help..

For sure I don't want to scratch the roof of Polar bear, after the rack is situated, I can drill the mounts on the "Footing" of the truck, to optimize the rigidity of it..

Is not perfect, perfect but I really happy, is only going to be about 4" taller than the truck, no more hitting height restrictions at parking lots..

 

[Patineto]

More updates..

The back can be set up upwards (fence for the kiddos) extended backwards, move downwards to serve as a step and also the front mounts fir a bicycle rack (only two, maybe three bikes)

Half height, with the grey triple clamps folded..

"Stairs"

All the way backwards, a little more than 20" increment is platform space..

I still need to precisely Cut the hanglider tubes so the two triple clamp, occupied the same space.

Sadly the wake board had to be cut, it will be great, to have it seal but it just did not fit..

the board is going to seat about a foot forward from the picture and also lowwer, basically touching the edge of the trucks front wind screen.

Remember the two hella lights go on those big holes..

 

[gandrimp]

Can you guess what this weighs?

 

[Patineto]

Can you guess what this weighs?

I use a scale to weight most of the parts (no bolts or brackets and so far is about 70 pounds, a little to heavy for my taste but not much I can do about it,..

 

[whitenoise]

@Patineto , very ingenious re-use of old parts! Wish I could do the same. I got this far with my 80/20 build, now to mount to the roof without a ton of trick machined components....

Waterjetted 1/4" thick 6061-T6 side profiles - Matches the roof profile exactly and has space to mount up to 10 of the 40-series 80/20 crossbars. I am starting with only 5 crossbars for my intended roof load. The total weight including all fasteners is 32 lbs.

The roof is not straight at all, but the big problem is how close the side profiles are to the holes on the roof, making a suitable adapter plate tricky to build. I do not want to shorten the crossbars from their standard 48" length if I can help it....

 

[Patineto]

@Patineto , very ingenious re-use of old parts! Wish I could do the same. I got this far with my 80/20 build, now to mount to the roof without a ton of trick machined components....

Waterjetted 1/4" thick 6061-T6 side profiles - Matches the roof profile exactly and has space to mount up to 10 of the 40-series 80/20 crossbars. I am starting with only 5 crossbars for my intended roof load. The total weight including all fasteners is 32 lbs.

View attachment 1402701

The roof is not straight at all, but the big problem is how close the side profiles are to the holes on the roof, making a suitable adapter plate tricky to build. I do not want to shorten the crossbars from their standard 48" length if I can help it....
View attachment 1402702 View attachment 1402703 View attachment 1402704

Good for you, very nicelly done..


If anything I oversize mine to much (MY purpose is to have a plaftform that my girls can play in, so the bigger the better (REason why for the massive longitudinal members.

I work on small plane and helicopters and a saw way to many rivnuts come updone (They can not take any side loads and even if the loads are on axis the surrounding material is very prone to get deformed.

So in my rack the rivnuts are going to hold a "Footing" a long strip about 3 1/2" wide and then the mounts are going to be attach to it, kind of a pain, but my hyper geekiness and pessimistic outlook push me that way..

good job in the windshield too

keep us post it

 

[Bud]

I like your creativity!