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  #1  
Old November 15th, 2010, 10:34 PM
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Jeff Davis
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Building a roof rack

Who knew learning how to weld and bend metal could be so much fun!!!! If you have 4 days and $300 bucks you can make your very own roof rack. That's right! $300. Granted, you need a few tools in your shop including a welder, drill press, table saw, grinder, and a few small things I don't even know the name of. Pics are below. Some of the welds are a bit chunky but give me a break, it was my first time. The outer tubes are 1.5 inch with 1 inch supports/steps. The flooring is a horse fence I stumbled on in OKC at a steel supply shop...not much fun making over 200 passes with the welder but it should hold around 1000 lbs according to my engineer helper. The basket is roughly 120 lbs and the ladders add another 40 lbs or so. Let me know what you think. Haven't painted it yet....that's black primer you see. More pics in post below....
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  #2  
Old November 15th, 2010, 10:38 PM
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Joshua
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good work, although it's hard to tell without a full pic of it mounted on the truck.
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  #3  
Old November 15th, 2010, 10:38 PM
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Jeff Davis
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More pics. For those curious I'm running 255/85/16 with 2 inch OME HD front MD rear.
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  #4  
Old November 15th, 2010, 10:46 PM
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Sorry. Technical difficulties. Here's the finished product....
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  #5  
Old November 16th, 2010, 12:01 AM
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Looks great Jeff!
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  #6  
Old November 16th, 2010, 02:10 AM
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I think the most important thing is that you did it yourself and you learned a lot doing it. You probably had fun doing too.
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  #7  
Old November 16th, 2010, 06:38 AM
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Looks great! Nice crossbars
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  #8  
Old November 16th, 2010, 08:36 AM
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It was nice meeting you yesterday and as I said then the rack looks great! For someone who has never welded before that was a pretty big under taking and you did a good job.
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  #9  
Old November 16th, 2010, 06:21 PM
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Thanks guys. The process was frustrating at times but overall a fun experience. Big thanks to Jonathan for the cross bars. Saved quite a bit of time. Guess I won't be buying a rack from you now but still think you have the 2nd best looking rack out there!!! Kidding. I like yours better than mine but couldn't pass up an opportunity to learn how to make one.
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  #10  
Old November 22nd, 2010, 07:22 PM
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NICE JOB!
(I'm wondering how many welding helpers are engineers!)

That's a great project and looks better than most!
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  #11  
Old November 22nd, 2010, 07:32 PM
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Thank you. The welding helper was an old timer that has been a jack of all trades. Rancher. Contractor. Horse whisperer. Civil engineer. Salesman. He's built skyscrapers, oil rigs, houses, highways, you name it he's done it. Couldn't have done it without him. You can clearly tell my welds vs. his......if you could even tell where his were. Welding is an art.
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  #12  
Old November 25th, 2010, 04:09 PM
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I have some chicken coop flooring from Farmtek I'm not going to use- you're more than welcome to it.
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  #13  
Old November 25th, 2010, 04:12 PM
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Thanks for the offer but I already built in the flooring..... Have a great Thanksgiving.
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  #14  
Old November 26th, 2010, 03:39 AM
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Looks great. The corner bends on the 1.5" tube look a little scary, what sort of bender do you have?
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  #15  
Old November 26th, 2010, 10:38 AM
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A local muffler shop bent the basket tubes. Squeezed a bit at the corners. If there's a next time I'd use 90's like I did on the ladder.
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  #16  
Old November 30th, 2010, 11:39 AM
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Looks great. One small eensy weensy thing...the round tube on your ladder rungs will be really slippery with muddy or wet boots. If it were me I would make them from either angle stock or use some expanded mesh on the tops.
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  #17  
Old November 30th, 2010, 05:21 PM
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Jeff Davis
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I initially tacked on square tubing for that reason and liked the look of the round better. But you're right, it is slippery when wet.
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  #18  
Old November 30th, 2010, 09:10 PM
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Nice job, Jeff. As for the ladder, just get some no-slip tape and apply to the rungs. Done. Hope to meet you at one of our Happy Hours. Mark
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  #19  
Old November 30th, 2010, 09:39 PM
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Quote:
Originally Posted by Oxcart13 View Post
Nice job, Jeff. As for the ladder, just get some no-slip tape and apply to the rungs. Done. Hope to meet you at one of our Happy Hours. Mark
Ditto- count me in for a happy hour as well
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  #20  
Old November 30th, 2010, 09:47 PM
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Quote:
Originally Posted by zeusdavis View Post
A local muffler shop bent the basket tubes. Squeezed a bit at the corners. If there's a next time I'd use 90's like I did on the ladder.
Next time you drive all the way to Oklahoma to build a rack you can use my Baileigh tube bender and notcher
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