Rack bed

[Nigel]

I found a nice homemade roof rack on CL a couple of weeks ago. Came off another FJ60. I scrubbed all the rust off and repainted it and now it looks quite respectable. (see pic)

When I got it, the rack had a particle board bed, which I removed. Just wondering what the options might be for a replacement. I've seen others with a plywood bed, but I was wondering about welded wire mesh, or even perforated sheet metal.

Anybody got any thoughts on pros and cons of these options?

 

[Randy88FJ62]

I like the low profile. Poeple go with plywood because it's strong and easy. I prefer mesh or something metal as you're alluding to.

 

[sirenmoses]

'search' here on Mud, and ye shall find.

atv ramps

expanded metal

oak slats....

etc.

nice score!

 

[Nigel]

Mmmm ... oak slats. I like the sound of that. Has that classic feel about it.

 

[2mbb]

On my first rack I used 1/4" plywood on mine for a while. From a weight and cost basis, plywood is hard to beat, but it really depends what your uses are. 1/4 inch is too thin to stand on, but I used it mostly for light stuff, bicycles, etc. I went to a local hardwood specialist (MacBeath Hardwoods) and got marine grade mahogany plywood. I didn't really use any finish and it held up quite well for several years.

My next rack was a home made aluminum rack. On this rack I used aluminum diamond plate. I used 1/8 inch thick because I wanted to stand/sleep on it. The diamond plate turned out to be heavier than 1/2 plywood and much more expensive.

 

[landcruiserjunky]

Maybe black diamond plating?

 

[Wile E Coyote]

I'm just over halfway through a DIY rack build myself, and plan to look at perforated or expanded sheet. I won't be sleeping, but would be standing on it. Depends a lot on the level of cross bracing you've got, I'd imagine.

 

[ntsqd]

Blatantly stolen from an Expi thread on this topic:
PolyMax Poultry Overlapping/Kennel Flooring - FarmTek

Another option, also blatantly stolen from Expi:
STARLITE XL - STARLITE XL Sheet - Order Online

 

[cruiser88]

I got one I need to sell one day...no way in hell am I shipping that big bastard...lol

 

[Nigel]

Great choices. That kennel flooring looks good, and isn't too expensive either.

I had thought about steel diamond plate, but figured it would be too freakin' heavy. Hadn't considered aluminum diamond plate. I'd probably need 1/8" thick sheets, which at just under 2lbs sqft, would make it twice as heavy as the kennel flooring, but still acceptable. I'm guessing my rack weighs about 70lbs (1" sq steel pipe). So, be nice to keep the extra weight down.

The aluminum diamond plate also costs a lot more though. The kennel flooring is $19 for a 2' x 4' sheet, and the 1/8" diamond plate is $180 for the same sized sheet (MetalsDepot). Diamond plate sure would look nice though.

I also thought about expanded metal sheet, but it seems to have jagged edges that might easily snag.