Tim's Lame-Ass Build Thread

[MissouriLC]

For the deflector, I wanted to a Prinsu/Dissent style full width deflector that snugs right against the roof. So, getting the curvature of the roof is going to be critical and challenging! I started getting the rough profile on a thick piece of cardboard, and then translating that to a piece of leftover plywood to make a machine jig.

I got it marked and cut an then spent several hours going back and forth and fine tuning the curvature.

When I was satisfied, it was time to execute it in plastic. I found a 4X8 sheet of 0.22 inch black HDPE from Menard's. I rough cut the shape with a jigsaw...

And then clamped it to my plywood machine jig. I used a bearing laminate bit on my router to maching the final edge.

 

[MissouriLC]

Here's the detail of the mounting system... one of the more clever aspects of my design, in my opinion. I fabricated this using off-the-shelf 10-series joining plates, and it mounts a 1X2 extrusion that the deflector is mounted to.

Finshed result! I am very happy with how it turned out, but the weatherstripping needs a bit of fine tuning.

As you can see, I used some 1/4 ID fuel hose as a temporary weatherstrip, but it looks janky and doesn't fully-fill the gap. I've ordered some bulb-type weatherstripping from McMaster-Carr, which should arrive tomorrow.

There is also an intermittent rattle between the deflector and the extrusion to which it is mounted. I need to add some foam or rubber between the two. However, the deflector WORKS perfectly... wind noise has been eliminated and it no worse/different that with the factory rack, that I can tell.

I'm also considering notching the top of the deflector to add a recessed, 24-inch single row light bar.

 

[JunkCrzr89]

Got everything snugged-up and added the side rails. Then I added the remaining three (3) cross bars.
View attachment 2295159

There's a total of six (6) 1X3 cross bars, plus a 1X1 end bar at the front, and a 1X2 end bar at the rear. The platform is completely flat across the top and rock-solid.
View attachment 2295160

I drove around with it a bit for two days with no front wind deflector, and the wind noise at 50mph and above was deafening! Time to start fabricating a wide deflector!

Looks great. Makes me feel like a loser for not finishing my modular aluminum rack yet...It’s been 90% finished for a couple of months now...

 

[MissouriLC]

Looks great. Makes me feel like a loser for not finishing my modular aluminum rack yet...It’s been 90% finished for a couple of months now...

Thanks! I'd love to see pics of the rack you're working on.

 

[JunkCrzr89]

Thanks! I'd love to see pics of the rack you're working on.

You have given me the impetus to dig it out from behind the junk it’s currently covered by. Which means I’ll have to finish it now

 

[MissouriLC]

Here's some new updates on my rig, from a busy summer/fall.

I made some additional adjustments and modifications to my roof rack. I added a recessed lightbar behind the wind deflector, and some airline L-track for quickly tying down loads. I also added a Smittybilt 8-foot awning on the passenger side.

The rack and additions came in handy for a bunch of camping trips we took over the summer. This was July 4th weekend:

That awning was key when we had a torrential downpour while setting up camp!

The heavy load of taking 6 people camping also made me realize how shot and saggy my shocks and rear springs were, as evidenced by the sagging rear end in the first photo.

Incidentally, that trip broke all four of the kids:

Based on a lot of good advice from folks here, I opted to replace the worn Monroe shocks that he P/O had put on with new OEM Tokicos and a set of Old Man Emu 2860 rear coils.

Seeking advice on shock and rear spring replacement

Then, later in July, we spent a Sunday with my brother-in-law's family at the Meramec River, about 60 miles from home. We packed up the truck to head to the shower house before leaving in the evening, at the charging light was on. Damn!

We limped home on the battery. The alternator, which was an "Ultima" branded remanufactured Denso core from O'Reilly's (which I had installed the previous December, so 7 months old) had completely died. Luckily, O'Reilly's took it back and refunded me cash under their lifetime warranty, and I replaced it with a Toyota-branded Denso reman from the dealer.

Input/confirmation requested... likely bad alternator

Then, earlier in October, I decided to attempt and respray my wheels. I used the Duplicolor Metallic Graphite wheel paint with Duplicolor's Wheel Clear Coat on top. It didn't turn out perfectly, but it looks 200% better than the previous oxidized, stained silver paint.

Here's how she looks today (or, as of Halloween, anyway):

 

[golfer2000]

You you mind me asking what youve spend on the rack? I can't wrap my head around these extruded rack companies charging what they do for something relatively simple.

Here's the detail of the mounting system... one of the more clever aspects of my design, in my opinion. I fabricated this using off-the-shelf 10-series joining plates, and it mounts a 1X2 extrusion that the deflector is mounted to.


Finshed result! I am very happy with how it turned out, but the weatherstripping needs a bit of fine tuning.


As you can see, I used some 1/4 ID fuel hose as a temporary weatherstrip, but it looks janky and doesn't fully-fill the gap. I've ordered some bulb-type weatherstripping from McMaster-Carr, which should arrive tomorrow.


There is also an intermittent rattle between the deflector and the extrusion to which it is mounted. I need to add some foam or rubber between the two. However, the deflector WORKS perfectly... wind noise has been eliminated and it no worse/different that with the factory rack, that I can tell.

I'm also considering notching the top of the deflector to add a recessed, 24-inch single row light bar.

 

[MissouriLC]

You you mind me asking what youve spend on the rack? I can't wrap my head around these extruded rack companies charging what they do for something relatively simple.

Going from memory, the extrusions, brackets, and all the fasteners was right around $400, including shipping. All the extrusions, the t-nuts, and most of the brackets came from tnutz.com. A few of the brackets and all the fasteners cam from McMaster-Carr.

The Gamiviti towers were another $250.

The sheet of plastic for wind deflector was about $50, but it’s a 4x8 sheet. I actually made two wind deflectors and a bunch of other stuff, and still have half a sheet left over!

I spent maybe another $200 on accessories, including lights, L-track, tie-downs, eyebolts, Quick Fists, etc. Then there’s the awning! I recall that was about $250.

So, I’m probably in it for $1100 at this point, fully-outfitted. But the base rack was built for under $700.

I do understand the cost. I can't imagine engineering those side rails is easy, particularly with the way the 100-series narrows toward the rear. My biggest concern with the Prinsu style racks is the way they mount with long bolts and cylindrical spacers in the roof channel. This seems like it would add a lot of dynamic moment loading to the bolt holes in the roof. The Gamiviti and Trail Tailor towers are a bent steel plate that rests against the sheet metal of the roof channel, thus spreading that moment load out over a couple of square inches.

The great thing about the t-slots is its like an erector set, and completely modular/customizable.

 

[golfer2000]

It's crazy how much of the budget is ate up by the brackets. Maybe I can do without a rack for a while lol.

 

[MissouriLC]

It's crazy how much of the budget is ate up by the brackets. Maybe I can do without a rack for a while lol.

Yep, but the Gamiviti towers are amazing! Totally worth the $250.