Roof Rack build

[zukrider]

since my expo zuk got totalled, along with the rack i built for it, i am going to build a rack for my SR.

this is in the ideas/prep stage. and i have a few questions. for those of you with racks, are you attached to the actory rails? or replacing the rails to use the roof mounts, which i assume are studs? either way, what are your opinions on its strength/stability/overall functionality?

i will most likely build it from 3/4" or 1" EMT again, with crossbars on 5" centers. my zuk rack was all 3/4" with 5" centers and it held my 265# on one bar with minimal bowing. mounting to othe roof is the biggest question as of yet.

its full time function will be lights, hilift, shovel/axe mount, and sleeping platform storage. the platform will be a plywood base @52x88". it will be 2 pieces, together with a piano hinge. it will go on the rack hinge down, and tie in with barrel bolts so as to be quick/cheap/easy. i didnt get to the platform portion with the zuk, but im convinced this system will keep it on and prevent movement, even in wind(crossing fingers). when not in use, it will fold up, and store under the rack, full time. easy deployment. it is based on an REI half dome 2 backpacking tent. i plan to also get a good 4 season 3 person tent in the future, and will build a platform for it accordingly.



please chime in with any info and suggestions you have, and thanx for looking. ill start getting measurements and drawings. pics as they come available.

joe

 

[zukrider]

here is the zuk rack being built

an overall.

its currently in the trash

 

[LaOutbackTrail]

Gutter mounts for sure.

These guys have excellent service. They expedited my mounts so that I could mount the rack the day before a trip.
http://www.diamondrax.com/

DO NOT mount to the flimsy plastic existing rack.

 

[RttH]

Gutter mounts.

 

[off-roader]

The OE rack is aluminum, not plastic.

That said, I'd use the gutter mounts. The OE mount location is probably only designed for very light loads.

 

[LaOutbackTrail]

Mine is ALL plastic. I know this because I cut it into tiny pieces to put it in the trash can..........................

 

[off-roader]

Mine is ALL plastic. I know this because I cut it into tiny pieces to put it in the trash can..........................

That's wierd. Was it possibly one installed by the dealer? The ones I've seen both on my rig on others have been aluminum. I know because the black paint had faded and the aluminum was showing through from underneath.

 

[LaOutbackTrail]

That's wierd. Was it possibly one installed by the dealer? The ones I've seen both on my rig on others have been aluminum. I know because the black paint had faded and the aluminum was showing through from underneath.

Not Sure, Ray...

It wasn't exactly plastic, maybe fiberglass reinforced plastic or something, because it had little fibers in it.

 

[zukrider]

interesting on your rack LA, mine is aluminum. ill look into the gutter mounts. i want to build them though. do you have any detailed pics of the mounts? both on and off?

thanx

 

[zukrider]

hey RogerH, do you have any info on your monty? maybe we could meet up sometime! if your interested, i am hosting a holy cross trip weekend of aug 19th, your welcome to come!

 

[RttH]

Sounds fun! Remind me as it gets closer to the date. I will be in Montana and Canada the first two weeks of August and then Wyoming for a backpacking trip sometime in August. PM me as I don't always catch these threads.

 

[fatrat]

I have been thinking about building a rack for my 1st Gen Monty. I built one years ago for my Frontier & it worked perfect. I made it out of angle iron but was thinking of going 3/4" EMT or 1/2" rigid this time round. Do you have any more pics of your gutter mounts?

 

[zukrider]

not many. the feet are made from 4" x 1/4" strap. the clamps are 1x2 .120 that i cut in half to make 2 "L" pieces. welded the 3/8 bolts to the clamp, and used round tube for the solid end of the foot piece. and a 3/8 lock nut.

i would not bother with 1/2 rigid, i dont feel the weight gain would be beneficial in strength at all. just make sure when you weld it, you either strip all the galvy or use muriatic acid. take caution to not die from inhalation.

good luck with the project.

here is the foot, sunk into the tube, so the top will rest on the foot, and then its welded around for added support and better stability.

solid portion of clamp

finished product

i plan to improve on the setup this time. a little cleaner to start. with this rack, the feet will a lot taller to achieve the gap i need for the sleeping platform. so i will use 4 per side, and i plan to put holes in the feet to lighten them up and provide extra tiedown access. i may even incorporate a better attachment to the rack. but in all honesty, the sami setup was strong. in the rollover, the sami hit guardrail face first, jumped in the air, and landed on the passenger roof corner. it f$%&*d my sami up, and the rack was just tweaked enough that it wasnt worth straightening. it held up surprisingly well. i will take more time to align the feet a bit better this time though.

 

[fatrat]

Great info! I am looking forward to seeing your finished rack.

Good luck!

 

[zukrider]

thanx. i had a lot of cool plans with the zuk. and most will transfer to this. i planned on making a ladder that bolted to the top and bottom of the rear door. it would have 3 steps. also, a second piece that hinged on the bottom and was wider to fit over the stationary piece. it would swing down to make a full ladder for my short girlfriend, kids, after i been drinking! when not in use, it will swing up and latch with something simple. Then i planned to make a dual jerry can rack that hooked to the ladder and locked on with a lock. the rack wont make it, but i plan a version of the ladder.

the ladder would lead up to the roof rack, which would have my sleeping platform on it, spanning the 88" length sideways so as to hang over each side. and my REI half dome 2 would be staked to the platform for an easy RTT. this plan is still in action, though i am thinking of ways to improve it.

LETS START HERE!



the original platform was to be 52" x 88". plan was to use exterior 3/4" plywood cut into 2 pieces of 52 x 44. coupled together by a piano hinge. stowed away it would fold up and slide under the rack and lock into place. deployed, it would lay over the back of the rack, hinge down. it would attach to the rack by slider barrel bolts in various spots so it wont lift or twist. as long as the plan worked, it would tip the truck before it ripped off due to wind.

to help make it durable, the plan was to coat the wood with white RV roof sealer, so it would be water resistant. also, i thought of framing the edges with aluminum C channel to help with warping.

here in lye the changes i am currently pondering. i have thought about making the platform of NOT WOOD. i really dont want to do it more than once. so i thought of an aluminum frame, maybe 1/2 or 3/4 square tube. still 2 pieces hinged. but covered in a sheet of 14 or 12 guage aluminum sheet with holes drilled in it for porosity. my issue with this is the cost could end up very high, not to mention i havent bought a spool gun yet. nor do i have money for it. i am totally up for ideas in this department. another thought was a cot like setup with a light steel frame and stretched canvas. this i have no idea on cost or where to start. though there is a well known hunting tent manufacturer down the way from me. hmm, i honestly just thought of the canvas setup.hmm.

anyhow. i want to mount small lights. and depending on how the height works out, i can mount them on the under side, leaving the whole top open. i dont plan to have a top rail. just flat with tie down loops for straps and bungees. the front lights will be a set of rigid industries D2's as spots. they will compliment the flood duallys that will go on front bumper. i dont have these, and have no clue when the budget will allow, but there planned!:ylsmoke: for the sides and rear, i will use some cheaper walmart rice rod style fogs, unless by then i find the right low profile led lights! i will build my own hi lift mount and either build an axe/shovel mount or buy some quick fist clamps.


please throw in some ideas and criticisms.