My First Truck Fabrication Project. Almost Done.

[StumpXJ]

Well, I managed to build myself something that im pretty proud of, atleast at this point. Im sure there are countles threads on roof rack build ups, but I still wanted to share.

When I got my Tacoma about 8 months ago, I couldnt decide what I wanted to do to it first... Rear Bumper, Front bumper/winch, sliders, roof rack... and like most, the list is a mile long.

I decided that the roof rack would be the best place to start, followed quickly by a rear bumper with an integrated spare tire swing out gate.

Here is my progress with the roof rack so far. I have $90 dollars in material (excluding lights), and I should have everything I need. Not bad considering the price of a manufactured unit is rediculous. I have spent the last two evenings (about 12 hours total) and I think its turned out well so far. I still have to do the following:

Make mounts for 2 rear lights and mount them.

Make lockable side mounts for my Shovel, Axe, and Hi-lift.

Make mounts to mount it on my camper shell with internal reinforcements for weight capacity.

Paint it.

And finally mount it and wire the lights.


The lights are cheap'os from ebay, atleast they have a H3 bulbs that are easily changeable, instead of a sealed beam. I paid a $90 bucks for 8 of them and figure I wont be out much if they are total crap. I love to replace all 8 of them with Light Force lights, but would have to rob the local bank to do so. Time will tell if they perform well enough. I also plan to mount the extra two lights on the front bumper when it eventually gets built.

~James

 

[crawler#976]

Looks great!

What size tubing did you use?

Mark

 

[articulate]

Certainly does look great. And what are the overall dimensions? (length, width, and depth)

 

[StumpXJ]

Thanks guys, the demensions are 7inches deep in the basket, from the top rail to the top of the bottom rail (about12 inches over all height at the top of the light hoop, no more parking garages for me!), 60 inches long overall (on the bottom, including the light shelf) 52 inches in length inside the basket, and 46 inches wide.

I used 1 inch square tubing, .090 thou. wall. The light protection hoop is 1/2 inch round bar, I made it a little high, incase I wanted to eventually go with larger lights.

 

[BogusBlake]

Nice! What are your plans to mount it to the roof?

Learning to weld with flux core or stick is the way to pick up good habits. If you can make those welds perty, you'll have no problem with a MIG.


I have to ask though- Is that square tubing made of gold or something? It looks like you have between 2-3 sticks there; around here, 1" 13 gage is about $20 a stick.

 

[StumpXJ]

Not sure yet on the roof mount, I will be making and internal frame inside the camper shell that matches up with the roof rack mounts, and will b bolted to the top of the bed rail. My goal is to be able to walk around on the roof rack when its all said and done. Just have to do some thinking and go for it...

Yeah, Ive been welding since I was 8 years old beleieve it or not. My dad has been in the fabrication business for 38 years, so I picked up a few things from him over time. When I was living in the States, I would just use his equipment, but now that im over in Germany 6000 miles away, I had to buy my own. The Germans have a different Gas set-up, different regulators, and getting a large bottle of Argon is next to impossible. They sell small 2 pound (for $30 Bucks!)bottles in the Baumarkt (like lowes or home depot) but that is pointless for larger projects. Hence the reason I went with flux core. I prefer MIG but its just not feesible while Im over here.

Look closely, its actually 5 full sticks, I had about 6 feet left over. The Dollar to Euro rate is in the toilet, so yes, it is kinda like gold. I was just glad to find a place that sells steel to the public, only took me four months of searching. Its very different over here, the language barrier, and the rules and regulations make it difficult to do what would normally be easy in the States.

Thanks!

~James

 

[p1michaud]

Roof Basket build

Not sure yet on the roof mount, I will be making and internal frame inside the camper shell that matches up with the roof rack mounts, and will b bolted to the top of the bed rail. My goal is to be able to walk around on the roof rack when its all said and done. Just have to do some thinking and go for it...

James,
Very nice fab skills. There are a few threads on this board about roof basket build ups: first attempt roof rack and DYI Roof Rack/Basket. You may be to far down the road with your build now, but my advice would be to build it as light at possible while making it strong enough to meet your needs. It's a balancing act. My roof basket is too heavy (like most other items I have build for the truck, like my sliders that are about 65 lbs each!).
Another good thread is this one on Roof Tent Mounting Options. Some of us with camper shells have discussed mounting solutions that may give you some ideas for mounting your roof basket.
Cheers :beer:,
P

 

[StumpXJ]

Well, its finished...almost. I still have to finish the inside support system, that will mount to the bed rail, although its pretty sturdy as is. I also still have to mount the axe and hi-lift on the passenger side. Waiting on a few items for that. I think it turned out great. Still have to aim the lights tonight, but its all hooked up and working!

Cant wait to finish my rear bumper/spare tire swing out gate.... Fabrication is so much fun... Turning a pile of metal into something you can be proud of! (and pround you only spent a fraction of what manuf's. want, and its exactly how you want it!)

~James

I did a little pre-planning a few weeks ago while I was waiting on my welder to arrive and fabbed up this switch plate. I fully wired it, including the relays under the hood and everything. All I had to do is hook the equipment into the back of the relays and it was ready. I ordered a camera system and it should be here shortly, the "fridge" is in and working along with the rack lights. The two front bumper lights will go on eventually, once the bumper gets built.

 

[RoundOut]

Very nice.

I love the look of your rack and the switch panel under the radio. I was thinking of a similar switch panel to be mounted in a future ceiling console, but now seeing yours, I am re-considering the location.

Question about your rack... It looks like you have mounted it with 9/16 bolts through the shell at a near horizontal placement of the bolts. Could you post a picture of your internal framing that allows your rack to support your weight? When you described your plans for this, I pictured something mounted more on top of the topper, rather than on the sides.

Great work! :bowdown:

 

[akraven]

Great looking switch plate setup. Very professional looking. What did you use for the labeling? Thanks. akraven

 

[StumpXJ]

Thanks guys.

Roundout, I still have to finish the inside portion. The reason I mounted it on the vertical sides is it supports more weight and is more structurally sound on the side with a top load. Kinda like laying a piece of carboard flat across a 2 foot gap and pushing down in the middle as apposed to sitting the carborad vertical and then puushing down on the edge.... you get the idea.

The inside rack will still be similar to what you are probably thinking, except it will be mounted on the sides of the shell and go down to the top of the bed rail, again to support the weight. When I get it finished, ill post up pictures.

Akraven, I used a 8.5x11 sheet that is basically like one giant label. Just typed it up on the computer, ran a few test "prints" to get the spacing worked out and printed it finally on the adhesive sheet, then cut it to fit the panel, pretty simple.

You can go to this thread on TTORA (dont worry its short) for more info and pictures of the panel and install.
http://ttora.com/forum/showthread.php?t=55681


Thanks again! My wife laughs now because every time I get out of the truck, I have to turn around and "check it out". ~James

 

[StumpXJ]

Yeah... My wifes on a business trip, and Im bored. Came up with this in MS Paint. Maybe this can explain it better than before.

~James

 

[RoundOut]

That's what I was thinking you would do.

That's what I imagined, I just thought your bolts would have been vertical on the top, mainly providing lateral movement security, and relying on the strength of your inner frame for vertical position strenth. What you have drawn there, is probably better than what I was thinking of. Will the rack actually rest on top of the fiberglass shell, or be suspended slightly above it?

Yeah... My wifes on a business trip, and Im bored. Came up with this in MS Paint. Maybe this can explain it better than before.

~James

 

[StumpXJ]

Im hoping I can get everything lined up as close to perfect as possible so that the weight of the rack actually rests mainly on the internal frame. I will have to see how it goes, but ultimately i would like to enlarge the holes in the shell to say... 14mm (the bolts are 13mm) and let it kinda "float" instead of relying on the shell for strength. Kinda hard to explain, but i have plan. Just have to execute it! Measure twice cut once...measure twice cut once... as long as I dont get impatient, itll work out....lol

~James

PS, I honestly think I could stand up there right now, with NO frame, but wouldnt wanna chance it. Besides, on the trails, all the weight shifts and moves....blah blah blah. Would rather be safe that sorry (read: dont want to have to buy another shell!)

 

[akraven]

Thanks for the reply James. I will hunt around for that sheet to make some for myself. akraven