DIY Roof Rack, Seanz0rz's Low Profile Rack

[04 Rocko Taco]

Well best of luck with the kickstart.

Hang in there brother.

[4x4mike]

Kickstarter? Very interested to see what you've got cooking.

I'm sure you've posted about your 3D printer's limitations before but I've got an idea for you.

Actually I've already read about people suggesting this but no one is jumping on it.

The front mud guards for my fender flares have dropped off the face of the earth. There are guys online willing to pay twice retail for a set. I don't know if there has always been a demand for them, guys removing the running boards, but it seems like there are interested buyers out there. For one our buddy Bill just bought another 4Runner with the same flares and will be needing a set.

This is JA's website where he has them pictured: http://www.top4runners.com/ja/additions1.html

Part numbers: 00547-35966DF (driver side), 00547-35961PF (passenger side)

If you think you'd like to look into it let me know and I can get some measurements for you.

[4x4mike]

Here is a link with current interest.

http://www.toyota-4runner.org/3rd-ge...6-df-help.html

[Seanz0rz]

8x8" is my max, so I would have to split that into 4 or more sections, and they would shatter at the first rock. I guess you could make a mold and try to repop them in silicone or something.

as for the KS, it is what we talked about at pismo. That's all I want to release now. PM me your addy and you will get a package in the next couple of weeks.

[Seanz0rz]

One of my New Year's resolutions is to finish projects.

Got out there today and cleaned up the rust that had accumulated over the last 5 months or so. That took a few hours. I then finished welding up all of the cross pieces.

I then fitted the risers and top tube on the rack, marked where I had to remove the galvanizing:




After all that grinding, I tacked it up and did the final welds:


Tomorrow it will get cleaned up and inspected, and some welds need to be ground down. Welds aren't exactly pretty, but they will hold. I also plan on drenching it in paint, so that should hide some of the ugliness.

[Seanz0rz]

Didn't work on it today. Earlier this week, I got food poisoning or something, and ended up pulling all the muscles in my back, stomach, and chest. Working yesterday made my back way worse. I am actually having a hard time walking, and bending and getting back up takes quite a long time.

I did manage to remove the Daylighters from the old rack and inspected them. The rubber gaskets were toast, and the covers were as well. I ordered new ones from KC, less than 30 bucks, most of that being the covers. I also ordered a DDM HID kit for them, so they will get swapped when I refurbish the housings, then I can mount them up all fresh and new.

Now I have just about everything I need to finish up. I will have to make some tabs or something for wiring, and I still need to figure out mounts, etc. Tomorrow I will actually remove the old rack and mock this one up to see about those things.

[Seanz0rz]

Got the front done today.

Right side tacked up:


All welded up:


And where the Daylighters will live:


In between the lights, I will put in a panel, but I haven't decided on tinted acrylic or black ABS. Acrylic I would have to buy, I think I am all out of sheets big enough for that. I have the tint though. I have a sheet of ABS, but I don't think it would look as good. It is nearly a 2 foot span between the two lights.

I could also fill it in with some very thin sheet metal that I have, maybe 28 or 26 gauge.

Next time I will be tossing it up on the truck and seeing how it all fits. Rear mounts will be easy, fronts not so much.

[Good Times]

lookin good sean! what's the weight lookin like? bet those bends are no fun to do

[Seanz0rz]

Weight isn't bad. I'll see if I can toss it on a scale before I mount it. Solid modeling had it at 45 or so pounds. I'm estimating 55 when its done.

[Kryptoroxx]

I think it looks pretty good and the weight sounds even better.

A metal grating might be a good idea if you put a floor in it. It would help keep the weight down and water would not puddle in it.

If I could weld worth a hoot this would be a fun project!


stamped and snail mailed