Roof rack build

[WCBlueSky]

I needed more space to carry gear for longer trips, so I built a roof rack. Here are some pictures of the build process.

Raw materials: 16 gauge 5/8" square tube, and 14 gauge 1" square tube.

I made the frame out of the 1" square tube. I don't have a round tube bender yet, but I wanted to reduce the "boxy"-ness, so I angled the corners.

Then I added cross beams out of the 5/8" tube.

Making all the welds was a bit tedious, but good practice.

I then made the upper "cage" out of 5/8" tube, and welded on some D-rings on for convenience in rigging.

 

[WCBlueSky]

I made a fairing of sorts, but still wanted to have D-rings in the front so I didn't fully cover the front.

Welds all ground down.

I made the gutter mounts out of 1/4 flat bar, and added gussets. I used 4 ladders to hold it in place while I positioned on the roof.

The gutter mounts use U-channel, with two bolts.

I also welded a "foot" on the bottom of the gutter mount to reduce the pressure on the gutter.

 

[WCBlueSky]

Primer.

And finished!

The first field test in southern Utah went well.

Here are a few shots with it unloaded:

 

[WCBlueSky]

When I tightened down the gutter mounts, the rack sunk a bit and it is now touching (or very close to) the roof, so I may add a 1/8" spacer on the bottom feet to raise it up a bit.

 

[SoTexCruiserDoc]

Primer.
View attachment 2461035

And finished!
View attachment 2461037

The first field test in southern Utah went well.
View attachment 2461038

Here are a few shots with it unloaded:
View attachment 2461039

View attachment 2461040

Very nice. How much do you think it weighs?

 

[I Lean]

Nicely done!

Do the D-rings rattle? That would be my only concern with what you did...

 

[WCBlueSky]

How much do you think it weighs?

The base was about 75 lbs, so add in another ~15 lbs for everything else, definitely under 100 lbs.

 

[WCBlueSky]

Do the D-rings rattle? That would be my only concern with what you did...

I've never noticed them rattling, like going over a washboard road, but maybe I just lumped it into everything else that rattles

 

[Zach R 86]

Really like your idea of feet for the gutter mount where it sits in the gutter. It seems like a lot of designs might have all the pressure on the outside edge. I’m thinking to mold a little of this soft plastic/rubber material I have, and then additionally wrap that in rubber motorcycle tube which I always have around. We are going to put a huge tent up there and up to 4 people. Going the clean it up still, but this is my basic idea. Now contemplated broader feet and just the rubber, no plastic.

 

[WCBlueSky]

I decided I needed more space, so I added one more rung on front and back:

I also braced the inside:

Now it covers more of the roof, I like it: