Roof rack build (3 Viewers)

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Joined
Nov 18, 2019
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Location
Sandia Park, NM
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.
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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.
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Then I added cross beams out of the 5/8" tube.
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Making all the welds was a bit tedious, but good practice.
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I then made the upper "cage" out of 5/8" tube, and welded on some D-rings on for convenience in rigging.
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I made a fairing of sorts, but still wanted to have D-rings in the front so I didn't fully cover the front.
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Welds all ground down.
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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.
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The gutter mounts use U-channel, with two bolts.
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I also welded a "foot" on the bottom of the gutter mount to reduce the pressure on the gutter.
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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.
 
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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.
 
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 :)
 
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.

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