DIY Roof Rack Gen 3

[Offroadmuch]

Shortly after I got my Montero I saw that I would need to get some kind of roof rack going for surfboards and any other outdoor gear. I looked at everyone's set up I could find here and any other site. I know I like to tinker and make things by hand. I also know that things can get heavy, complicated, expensive and time consuming. Fast-forward a few weeks and I purchased a kayak. I still had no roof rack but I had a plan.

I started with a piece of plain metal stock from Home Depot, 2"x36"x 3/16" This would become the mounting bracket. Then some strong simple cross bars. I almost got some off Amazon or Ebay. But no. Again at Home Depot, I got a 1"x6"x8feet piece of smooth clean Poplar. Fine grain and strong. I borrowed my buddies router and a 3/8th round over bit for all of the edges to reduce wind noise. I picked up some outdoor varnish and put on 3 coats and let them dry for a week outside.

I cut the steel to about 2.5" lengths and drilled 4 holes per piece. Then spray painted it black for some rust resistance. I should mention that I purchased all stainless steel nuts and bolts for attaching.

The rest I will simply show pics and you will get the idea. The nuts are nylock so they should never come loose. And yes I did drill through the factory roof rails. I think it is pretty strong. I have used it every weekend for the kayak which is 80 pounds and 13 feet long. Does not budge at freeway speeds with a ratchet strap on each crossbar and a bow line. I tested the wood before I put them on and the only flex a little with 200 pounds on them. I would never plan to put that load up top but good to know they are sturdy.

 

[Offroadmuch]

I should mention that I have about 1" of clearance from the bottom of each crossbar to the roof of the Montero. Even with the kayak stapped down with some board flex. I do get some wind noise but not much. Almost nothing in the city and at about 75 mph it is about the same as overall road/wind/tire noise. I always make sure I tie down to the crossbars and not the factory aluminum rails so that all of the stress is isolated to the wood and not the rails or roof. Very happy with it so far.

 

[DeltaFry]

Nice and thanks for sharing....

 

[SONICMASD]

nicely done! I heard the stock roof rack has a max weight capacity of 75lbs. I wonder if that has to do with the horizontal crossmembers or the 2 long bars bolted to the roof? Either way, seems to be working great for you.

 

[Jvdkooij]

Why did you use the metal mounting brackets?
If I were you I would have made the wood about 2 inch longer and put it on top of the roof rails.

 

[Offroadmuch]

You could easily do that and it would be fine. I was trying for "low profile". It would have been much easier. If anyone is thinking of how to do it the most simple way then you are right. I thought it might help reduce wind noise but I will never know. I did think about it after that if I ever replace the wood I could extend the new pieces and just use the existing mounting holes. I will see how it goes for now.

 

[Offroadmuch]

nicely done! I heard the stock roof rack has a max weight capacity of 75lbs. I wonder if that has to do with the horizontal crossmembers or the 2 long bars bolted to the roof? Either way, seems to be working great for you.

I have read here on ExPo that it was 150 pounds but I am not really sure. I watch my kayak through the sunroof when I drive and it it very stable. I would dare to say that I have one of the lightest roof racks you can get, especially compared to the metal contraptions and Yakima, Thule type bolt on racks so that creates much less stress on the attachment points to the vehicle due to wind or wobble when offroad. I also made a piece of 1" finished plywood that is just narrower than the crossbars and almost the entire length of the roof to hold misc. objects if I want to strap down a lot of stuff for a trip or one of those waterproof roof bags. Again, very simple, very strong, very low profile. Have not had to use it yet. Covered in varnish and rounded all the edges. Should be ok to hold stuff as needed.

 

[Offroadmuch]

Just saw a post about Gen 3 roof racks and realized I never added these pics. Very simple, strong, cheap and quiet. 1" finish grade plywood top with outdoor varnish and some angle iron rails for strength and attaching tie downs. Could have made the plywoood longer and wider and skipped the crossmembers and steel hardware if I just bolted it to the existing factory rails but I made it up as I went along. Sunroof still has room to open although a small part of it is coverd by wood. I never open it anyway. I think I am the only Montero guy who does not care for sunroofs. I got all of the wood off of the scrap pile in the back of Home Depot for 70% off and the angle iron was free.