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:


Side:


Top:


Isometric:



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