Roll Cage Clamp for Front Runner Rack - Defender Source
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  #1  
Old May 19th, 2013, 04:12 PM
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Carl Jonsson
1995 NAS D90 #219
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Roll Cage Clamp for Front Runner Rack

I'm in the process of designing and having fabricated a roll cage compatible foot that clamps onto the roll cage that is specific to Front Runner Racks. All built in Solidworks and I am about to have the clamps machined and test fitted. After extensive research I found that no wide clamps exists, particularly not out of aluminum. Does anyone here have access to a CNC and would be willing to help machining the clamps? I have quoted several local options. All doable just crazy expensive.
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  #2  
Old May 27th, 2013, 02:17 PM
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I'd post a PDF of what I want done on both practicalmachinist.com and cnczone.com "request for quote" sections.

Works pretty good for small run stuff.

Oscar
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  #3  
Old May 27th, 2013, 04:24 PM
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Cool idea. Would love to make a low profile rack like that work on my 97 ST so I could fit in the garage.
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  #4  
Old May 27th, 2013, 09:48 PM
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Carl Jonsson
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Front Runner racks are as low profile as they get. Only problem is they don't make roll cage clamp feet. That's where these would come in handy.

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Originally Posted by kylesrover View Post
Cool idea. Would love to make a low profile rack like that work on my 97 ST so I could fit in the garage.
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  #5  
Old May 27th, 2013, 09:50 PM
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Carl Jonsson
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Thanks. I got 4 local quotes and settled on a place that is one of the more affordable ones as well as close by. I'm just surprised that no one makes aluminum roll bar clamps in different widths.

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Originally Posted by BlackField View Post
I'd post a PDF of what I want done on both practicalmachinist.com and cnczone.com "request for quote" sections.

Works pretty good for small run stuff.

Oscar
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  #6  
Old July 3rd, 2013, 03:48 PM
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Carl Jonsson
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Progress update. Clamps are done and I am test fitting them now. Ran into a snag though. There are two bumps on the inside of the NAS 90 cage near the joint where the front meets the rear above driver and passenger window. Any idea what these are and what happens when I grind them off? I need to grind them off in order to have the cage clamp fit correctly.
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  #7  
Old July 3rd, 2013, 11:01 PM
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Carl Jonsson
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Test fitting the new feet before paint.
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  #8  
Old July 4th, 2013, 07:10 AM
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This is exactly what I need for my Double Cab! Keep me advised, very interested.
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  #9  
Old July 4th, 2013, 07:19 AM
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I am in the process if fabricating something similar for another member here on his 110. Glad you were able to source something for the clamps.
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  #10  
Old July 4th, 2013, 09:17 AM
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Legs came out great! Of curiosity, which stock gutter legs are you using - the low or the high? BTW, you have enough support on that rack to put another 90 on top of it!
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  #11  
Old July 9th, 2013, 02:53 PM
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Carl Jonsson
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I got the 245MM legs as I wanted more than 1" of clearance from the roof so that I can fully open the sun roof and also be able to get a hand in there to wipe the roof off.

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Originally Posted by nuclearmonkey View Post
Legs came out great! Of curiosity, which stock gutter legs are you using - the low or the high? BTW, you have enough support on that rack to put another 90 on top of it!
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  #12  
Old July 9th, 2013, 02:56 PM
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Carl Jonsson
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Dropping the legs off for powder coating this week.

I realized a potential flaw with my design. The clamps are aluminum and the bolts are stainless. This will eventually cause galvanic corrosion, right? Is there anything I can do to prevent this?
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  #13  
Old July 14th, 2013, 03:37 PM
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Carl Jonsson
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Powder coated and installed.

Will run into issues having SS bolts in these aluminum clamps?

I covered them in anti-seize.
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  #14  
Old July 15th, 2013, 09:41 AM
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Quote:
Originally Posted by Manimal View Post
Will run into issues having SS bolts in these aluminum clamps?
I doubt it, unless there's going to be an accumulation of electrolyte in a liquid suspension.
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  #15  
Old July 15th, 2013, 02:38 PM
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So would these work on a front runner 110 rack with a cage?
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  #16  
Old July 15th, 2013, 02:42 PM
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Carl Jonsson
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Definitely. They'll actually work better on a full cage than a half cage. Going through the process I learned that the half cage was not installed level by Mantec/LR so I have to create some spacers in order to make the rack level. This wouldn't be an issue with a rack that is just mounted to the roll cage (not using a combo of cage/gutter mounts).

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So would these work on a front runner 110 rack with a cage?
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  #17  
Old July 15th, 2013, 03:10 PM
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Awesome, it's next on my list after the cage goes on. I'll be in touch
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  #18  
Old September 25th, 2013, 12:57 PM
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Carl Jonsson
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For those of you who are interested there are now some wider roll bar clamps on ebay that are a fraction of the cost of my custom ones.
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