R_Lefebvre
Expedition Leader
I'm going to start building a roof rack for myself. I can't really justify paying $1000+ for a rack, plus I have a TIG welder and it's fun, so, what the heck.
Just wondering if anybody has any input on design features?
I don't think I intend on ever having a rooftop tent. So I don't need super strength. But I would like to potentially put some gas tanks and or a wheel up there. The main use however is just light weight gear. If the potential of having gas tanks and wheels up there means the difference between a light and sleek rack, or a bulky beast, I'll opt not to put those up there. I'm trying to have the thing be light and sleek for CG and wind resistance reasons. I do want to be able to walk around up there for accessing gear.
I'm also going to make it out of aluminum because I like working with it, it's light, and doesn't rust.
I was thinking using the factory 04 rack tubes as the foundation for the front secton. Just because they're there, they seem strong enough as-is, and it saves making 4 drip rail legs. I also think it will result in the whole thing being lighter, and sleeker (style and MPG). I've already got two 1x2x.125 cross bars bolted to the factory tubes using U bolts, and a SportRack on top of those. Seems to work ok so far.
Is there any reason why I would WANT to have driprail legs? Any reason to have them?
In the rear, I'm not sure if I want to use driprail legs down to the C and D pillar, or work the mounting frame to support at the rear where there are factory supports under the sheet metal for the factory rail extensions. There are some reinforced points back near the rear door.
Again, this would keep the whole thing sleeker. The only reason I can think I might want them is to provide me a place to mount bridging ladders I might want at some point. The hilift is already on the bullbar. Shovel and axe are probably going to go on a custom spare tire mount.
The only other reason I can think I might WANT driprail legs, is to be able to weld a tube around them which serves as a "roof slider"? I've seen this mentioned. Not sure if it's worth considering.
I also think I'm going to add a wind deflector on the front, with a ramp angle which matches the factory tubes, and will carry into the front edge of the rack.
I was thinking the floor will be two-level. With the crossbars bolted to the factory rail tubes, I can still open the front sunroof. But, the rear floor would have to kick up a bit to be able to open the rear. I was thinking the top rail around the rack will be a single level however. So it will be ~6" high in the front, and 2-3" high in the rear. Just enough to give something to lash to. This design would hopefully complement the lines of the stepped roof, while still being sleek on top.
Thoughts?
Just wondering if anybody has any input on design features?
I don't think I intend on ever having a rooftop tent. So I don't need super strength. But I would like to potentially put some gas tanks and or a wheel up there. The main use however is just light weight gear. If the potential of having gas tanks and wheels up there means the difference between a light and sleek rack, or a bulky beast, I'll opt not to put those up there. I'm trying to have the thing be light and sleek for CG and wind resistance reasons. I do want to be able to walk around up there for accessing gear.
I'm also going to make it out of aluminum because I like working with it, it's light, and doesn't rust.
I was thinking using the factory 04 rack tubes as the foundation for the front secton. Just because they're there, they seem strong enough as-is, and it saves making 4 drip rail legs. I also think it will result in the whole thing being lighter, and sleeker (style and MPG). I've already got two 1x2x.125 cross bars bolted to the factory tubes using U bolts, and a SportRack on top of those. Seems to work ok so far.
Is there any reason why I would WANT to have driprail legs? Any reason to have them?
In the rear, I'm not sure if I want to use driprail legs down to the C and D pillar, or work the mounting frame to support at the rear where there are factory supports under the sheet metal for the factory rail extensions. There are some reinforced points back near the rear door.
Again, this would keep the whole thing sleeker. The only reason I can think I might want them is to provide me a place to mount bridging ladders I might want at some point. The hilift is already on the bullbar. Shovel and axe are probably going to go on a custom spare tire mount.
The only other reason I can think I might WANT driprail legs, is to be able to weld a tube around them which serves as a "roof slider"? I've seen this mentioned. Not sure if it's worth considering.
I also think I'm going to add a wind deflector on the front, with a ramp angle which matches the factory tubes, and will carry into the front edge of the rack.
I was thinking the floor will be two-level. With the crossbars bolted to the factory rail tubes, I can still open the front sunroof. But, the rear floor would have to kick up a bit to be able to open the rear. I was thinking the top rail around the rack will be a single level however. So it will be ~6" high in the front, and 2-3" high in the rear. Just enough to give something to lash to. This design would hopefully complement the lines of the stepped roof, while still being sleek on top.
Thoughts?
So I don't mind. :shakin:
