Building own roof rack!
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Building own roof rack!
Morning all
I am thinking of building my own roof rack and any suggestions and advice would be great.
My thought is to use 20x3mm flat bar to make it light but robust and as welding of aluminiium is a crazy
experience, I thought that would be the best. Also working with steel is far easier and it means bits can be added if necessary.
Any thoughts
I am thinking of building my own roof rack and any suggestions and advice would be great.
My thought is to use 20x3mm flat bar to make it light but robust and as welding of aluminiium is a crazy
experience, I thought that would be the best. Also working with steel is far easier and it means bits can be added if necessary.
Any thoughts
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Re: Building own roof rack!
Rather use tubing. It is much more rigit then flatbar. A lenght oh flatbar will bend under its own weight and is heavier then tubing.
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Re: Building own roof rack!
Thanks Bennie, good suggestion. The only problem I have with using tubing is the bending.
Is there anywhere that sells corner pieces for tubing? Kinda like the corner pices used for gazebos etc.
Might make it a bit easier than getting someone to bend to the "right angle" :D
Is anyone aware of where to buy the correct roof rail attachments, I suppose a hardware would sell them?
Is there anywhere that sells corner pieces for tubing? Kinda like the corner pices used for gazebos etc.
Might make it a bit easier than getting someone to bend to the "right angle" :D
Is anyone aware of where to buy the correct roof rail attachments, I suppose a hardware would sell them?
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Re: Building own roof rack!
You mean like this?
See Whitters post home made drawer system using this stuff. viewtopic.php?t=52 You can even use Aluminium tubing to bring the weight down.
See Whitters post home made drawer system using this stuff. viewtopic.php?t=52 You can even use Aluminium tubing to bring the weight down.
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Re: Building own roof rack!
I have had a look at that route thanks Bennie and Yes aluminium could be used, I'm just a bit worried about the lifespan of those joins when subjected to the elements all the time. I guess with them being so cheap, you could afford to replace them every once in a while.
However I will be building a drawer system to so maybe I should just match it and wait and see how long they last.
However I will be building a drawer system to so maybe I should just match it and wait and see how long they last.
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Re: Building own roof rack!
What worries me about them joints is that the pop rivet's hole might grow with the continuous vibration of million and millions of kilometers of dirt road.
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Re: Building own roof rack!
Hi Guys
The only way really to do it would be to use alli square tubing as Bennie sugests but I would weld the frame up and then make the roof mounts stiff rubber mounted to prevent longterm cracking and to releave stress on the frame.
The only way really to do it would be to use alli square tubing as Bennie sugests but I would weld the frame up and then make the roof mounts stiff rubber mounted to prevent longterm cracking and to releave stress on the frame.
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Re: Building own roof rack!
Pieter, I can agree with you on the rivets and it does kinda make me shift towards welding.
CM, any idea on costs of welding if getting someone to do it? Normal welding is not a problem for me to do myself but aluminium I have never touched. Any suggestions besides buying a ready made one, wheres the fun in that?
CM, any idea on costs of welding if getting someone to do it? Normal welding is not a problem for me to do myself but aluminium I have never touched. Any suggestions besides buying a ready made one, wheres the fun in that?
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Re: Building own roof rack!
Scooter wrote: Any suggestions besides buying a ready made one, wheres the fun in that?
You are like me. Even if the raw material would cost the same as the bought product I will rather build it myself then to make the 4x4accessories store owner rich. ANd you can enjou your handy work afterwards.
I hear they say that you can weld Alu with one of these AC/DC TIG Welders. Its maybe a good idea in the long run to invest in one.
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Re: Building own roof rack!
I read an article yesterday, written by a guy who had never welded aluminum before. He went out and bought a TIG welder and taught himself how to weld.I hear they say that you can weld Alu with one of these AC/DC TIG Welders. Its maybe a good idea in the long run to invest in one.
The problem being is how much do you throw away while teaching yourself the tricks. The main rules of thumb that he talks about are cleaning the material, pre-heating and using a heatsink to absorb excess heat.
It seems like quite a job but perhaps it is one of the trades guys like us should learn.
Have a read and see what you think :
http://www.artsautomotive.com/HowToWeldAluminum.htm
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Re: Building own roof rack!
I think the best thing to do is to cut all your material to size in your own design and when you are ready to weld get a pro to do it for you because the last thibg you need is for your own welds to fail miles from no where and the old battery method of welding will not cut it for alli.
It will be the proverbial up the creek without a paddle senario. On top of which alli is very expensive to waste.
It will be the proverbial up the creek without a paddle senario. On top of which alli is very expensive to waste.
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Re: Building own roof rack!
Forget about welding aluminium yourself. I see myself as a rather good welder of steel. I tried welding aluminium on several occasions and it is not that easy to learn. If there is too much heat a big hole just falls into your work piece, so big that you cannot weld it close. Aluminium is not like steel that will become red when it gets hot, it stays the same colour and the next moment, whoops, you have a 5cm big hole in the plate.
Either you do it in steel or you take it to a pro to weld.
A double cab's roof is not that huge. So the roofrack will not be that heavy. One of my friends used rectangular tubing which looked very nice. It almost looked like very thick flatbar. I do not know the exact size but it was about 20mmx10mm rectangular tubing which he used standing up.
If you are concerned about rust, get it galvanized.
Either you do it in steel or you take it to a pro to weld.
A double cab's roof is not that huge. So the roofrack will not be that heavy. One of my friends used rectangular tubing which looked very nice. It almost looked like very thick flatbar. I do not know the exact size but it was about 20mmx10mm rectangular tubing which he used standing up.
If you are concerned about rust, get it galvanized.
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Re: Building own roof rack!
Pieter
Do you have one of these TIG welders?
Do you have one of these TIG welders?
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Re: Building own roof rack!
Watching my dvd "a 4x4 is born" the guy has a cool trick for welding Aluminium
he puts dish washing liquid on the surface and when it changes colour it is the correct temp. Its sort of an indicator he reckons.
Even he struggles to weld the aluminium though.
he puts dish washing liquid on the surface and when it changes colour it is the correct temp. Its sort of an indicator he reckons.
Even he struggles to weld the aluminium though.