DIY "No Welding" Roof Rack

[Reconnoiter]

Can't find a roof rack that does exactly what you'd like? Want to build your own, but don't have a welder? Or, you can weld steel, but it's too heavy? I found a solution. 3/4" (ID) Schedule 40 (thick wall) Aluminum Speed-Rail. If you can use Tinker Toys, you can not only build your own rack, but you can change/add-on/redesign anytime you want. All you need is a Sawzall (or angle grinder or chop saw) & a 3/16" allen wrench!!!

http://www.hollaender.com/?page=sliponfittings

I also used 1" Square Tube (1/16th wall) as a "Floor".

I work as a Rigger in the Film Industry. We build stuff out of the 1 1/2" version on this stuff all the time.

Examples: http://www.all-in-one-truck.com/rigging.htm

If you want to build your own, feel free to contact me, if you have any questions.

 

[Zeiderman]

Now that's awesome, how long have you had it on? Payload? Cost of your rack? Last one, how did you connect it to your roof?

Sent from my SM-T230NU using Tapatalk

 

[Reconnoiter]

I don't put more than 100lbs up there, but that's because of the "Tip" factor. It could easily handle double that.

 

[tommudd]

So how much would a similar rack cost material wise?
Looking at the fittings seems pretty expensive by the time you buy them all??

 

[Reconnoiter]

I built it several years ago, but it was much shorter. I recently replaced the vertical pieces with longer ones, so I could add the Hi-Lift, shovel, and axe. It will hold more than you should carry up that high. I attached it with "L" brackets screwed into the factory rails.

 

[Reconnoiter]

It's not cheap for sure. I've got over $400 in mine. I did it because it's exactly what I wanted and I can change it easily. My next upgrade is to put four 9" LED flood lights on the front. I can add a cage around the lights for around $100. I can also easily add supports to carry a canoe, or a couple kayaks.The options are endless. You can even build a ladder, to get up there, out of the same stuff.

 

[dshirt]

Does anyone have experience with Esto Connectors. I built a platform for the cargo area of my series 80 using 1"square aluminum tubing and esto connectors. Covered with 5/8 plywood and carpet. Have 14" high by width of the cargo area of storage away from prying eyes. Bought tubing pre cut for $60 and connectors cost $40. Took 20 minutes to construct frame.

Now would this work for a full size rack (7 foot) rack maybe using 1 1/2" tubing and the connectors. Would need aluminum gutter mounts which I could probably fabricate. Would it hold enough weight so that one could sleep on it in a tent cot. I have posted this to their company website.