DIY Roof Rack, Seanz0rz's Low Profile Rack

I love my old Surco rack. It has served me well, but it is starting to rattle again, despite me adding a few dozen screws a few years ago.

I have decided to build my own light weight, low profile roof rack.

Goals:
Light weight, <60 pounds
Low profile, <7 inches
Mounts for Lights and HAM antenna
Maximize storage area
Look damn cool


I have decided to use 1" EMT conduit. With an OD of 1.163" and a wall thickness 0.057", it is really close to what I would use in regular structural tube. Plus, I can get a hand bender for under 70 dollars!

I have acquired some of the conduit, (I will likely need a few more sticks since I changed from my original design), the bender, hole saw to notch the tube, and acid to strip the zinc coating off the tube for welding. If I feel motivated tomorrow, I will start making it!

Since Solidworks is my poison of choice:

Front view:
http://farm6.staticflickr.com/5452/9...7416e8d4_c.jpg

Side:
http://farm8.staticflickr.com/7453/9...56a6c741_c.jpg

Top:
http://farm8.staticflickr.com/7458/9...3952547b_c.jpg

Isometric:
http://farm6.staticflickr.com/5478/9...c234fccc_c.jpg


I am also trying out Flickr. I hate it so far.

is the front spot opening specifically for your moonroof and also double for the light bar? how about reinforcing it with a lower tubing to attach it to?

thoughts on using alum to shave some weight? or doesn't make that much of a difference?

how about mounting points and hardware? how do you plan to mount it to the roof?

just throwing questions at ya since I'm bored :)

the forward opening is for the moonroof. I do use it enough to warrant leaving that section open. That forward bar actually sits just ahead of the opening and will have mounts that attach to the roof with industrial double sided tape. It will have light mounts for a future LED bar up front, plus lights on all the sides, etc.

Mounting will be through the factory tracks. I haven't drawn them up yet, but have them in my head. the front mounts will stick to the body ahead of the moon roof, but be detachable (so I can take the rack off if I need to)

I have no way to weld aluminum, so that's out. Currently, mass is at 45.37 pounds. With mounts, tabs, etc, it should be under 60.

hardware will be SS or grade 8, haven't decided. There won't be much, just to attach the rack to the roof.

Sadly, the happy faces will not be returning :(

mounts for the factory tracks:
http://farm6.staticflickr.com/5331/9...c234e05b_c.jpg

Something sorta similar for the forward mounts to the body, but without holes and probably lower profile. I will figure out those later

cool!

I like the idea of a low profile rack. I built one, there is a thread here on UY, to fit within and below my Yakima bike rack. The idea was to have something up there that wouldn't make any noise and not stick up so much that it drew too much attention to.

A couple of questions about your design. Do you know what you're going to be carrying up there? Are those items worked into your design? I use mine for lightweight soft goods, firewood and the mount/cage for two Specter MWC's. Rarely is it all of that but if it were it would be close to 175 pounds. I've got a lot of reinforcement as well as expanded steel. Your design has a lot of open space. Are there any plans for cross bracing or reinforcement for your cross bars? The emt is strong but with enough weight in one spot you'll kink the bars. I've seen plently of Yakima and Thule bars bent with 100 pound loads.

Another question is the front extension. What about the wash board roads rough trails? Do you think that bar will stay put and not smack the heck out of your roof? I've had thick Yakima bars vibrate enough to allow ski bindings from skis that are in ski mounts touch my roof. I'd talk with guys that have the Baja Racks or ROLA racks that have a similar design. My old full size truck had a lumber rack on it when I bought it and the hoop that extended to the windshield would move around quite a bit on the freeway.

Looking forward to your build. I've been thinking about building another version of the rack I already have since I pulled my Yakima rack off. I don't need extra room up there but I've got ideas in my head.

These are old cell phone pics but here is an idea of what mine looks like loaded.

https://lh5.googleusercontent.com/--...0716001639.jpg

https://lh3.googleusercontent.com/-c...716001639a.jpg

https://lh5.googleusercontent.com/-K...0716001640.jpg

I don't have much of any sides to my rack, just tie downs. The MWC cage is bolted through the expanded steel when it's used and everything else is just tied down real well. I know you've got your rocket boxes and pull pall. Make sure they can fit or that there is space for tabs for them.

sean,

how are you going to join the straight parts to the curved parts or is it one gigantic piece? do you have a tube crimper? thats what i'd use w/ the tube bender for the corners. do you have both?

Bob, each 10 foot section will have 2 bends in it, creating the "U" shape at the back of the top section and the front and back of the bottom. The very front section will have to be made in individual bends and then welded together because of the complex angles. . Everything will be welded together, and the butt joints on the tubing will probably get internal sleeves as well.

The planned use for the rack is primarily chairs, tents, empty water jugs, etc. Basically super light weight stuff, never more than 100 pounds, and probably never more than 50. I try to keep all my heavy stuff low on the vehicle.

I am not too worried about the front hitting the roof. It will be secured, and the tubing should be flexible enough to bend with the body if necessary.

I am going to wait until I get back from the trip this weekend to start. In the mean time, I will finish off the mounting brackets, light tabs, etc. Some of it will change when I get to putting it together, but it should be a good start.


edit: forgot to add, I will be putting down some type of expanded metal on top. I haven't picked anything out yet, but will soon.

I've changed my mind a few times since I posted up last.

I have decided on this:
http://farm8.staticflickr.com/7367/9...78703f44_c.jpg

Right now it is at 40 pounds. Once it is all done I expect it to be around 50-55.