All of the easily commercially available racks that are around for 2nd Generation Tacomas use the bed rail system. Which, I feel will not withstand heavy abuse with the weight of a roof top tent/Hi-Lift, etc.
I lurk a lot here reading many builds and projects. One of these days I will take a swing at my own trailer but here is the very first part I made for my 4runner. If there's anything that looks like your rack it's because I found this thread before designing it. So many awesome ideas in this thread and I added a few of my own hopefuly.
I added reinforcing to the inside of the roof to keep the front mounts from wallowing out and to spread the weight more evenly.
To help with making the frame level I cut triangles out of the inside to make my bends and then welded them back up. It worked very very well even with my horrible welding skills.
Wow! Some good stuff on this thread! Great ideas...thanks to all that shared. I'm thinking about doing one out of aluminum conduit and will post pics if it ever happens
Finished mine recently. Well, finished is such a strong word. I still have the LED side lights to mount and some other random things, but for the most part it's finished. Used a free cycled set of heavy duty contractor bars as the base. I walk around on it with no problem, but is still light enough that I could easily pick it up. For my needs and typical areas I went with best communications mounting locations over snagging tree branches. All the antennas are cheap as antennas go, even the dual band and the wilson, which isn't pictured here), so I'll see how it goes. They might get moved or I might make folding mounts.
I welded one up for the Montero this past year. It's designed to accommodate plastic poultry flooring if I want to have a solid platform for photography, air shows, etc. The cross bars are heavy-wall electrical conduit. There's almost no deflection at all walking on them.
I removed the factory cargo rails and created a low-profile mounting rail system from aluminum channel.
I welded mounting feet to the rack, each having two bolts that secure it to the tracks. It pops on and off in 5 minutes.
It's very stout without being ridiculously heavy. I built it short to allow full access to the Montero's enormous sunroof, but the tracks extend all the way forward so that a front crossbar could easily be mounted if the need arises.
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