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Old March 15th, 2010, 10:08 PM
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Tyler Graves
1997 D-90
Join Date: Dec 2007
Location: Framingham, MA, USA
Posts: 24
Custom rack gutter mounting options

I've been saving up for a new welder and I finally got one about a month ago. The first "big" project is a custom aluminum rack for my '97 D90.

I'm looking for any leads on where to get the gutter mounts, or additional opinions on making my own. I'm making the whole rack myself, and wouldn't mind saving a little time and buying a good set of reliable mounting hardware. Basically I need something metal that I can bolt my rack onto. Probably 4 each side.

Going to affix a Hannibal tent to it, and all sorts of other stuff as time goes on. Will probably add a ladder quickly after I realize how much of a pain it will be to get stuff up there without one.

Construction will be all aluminum, 3/4" OD (1/8 wall) square tubing. I'm sure people have opinions on the aluminum choice. I can weld steel pretty well, and AL is coming along nicely. Will be a great learning experience!


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Old March 16th, 2010, 09:19 AM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,538
Maybe buy some racks that have the gutter mounts you need and modify them as needed to be the base of your new rack?

Please share pictures of your progress!

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Old March 16th, 2010, 10:29 AM
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Wolf Fabrication
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Sterling Archer
'93 NAS110 #463
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Join Date: Sep 2007
Location: Oahu, HI
Posts: 7,348
I'm convinced there must be a source for them. I could use a plethora of them.
"The most unreliable car in the world is the most reliable car in the world." -Jeremy Clarkson refering to the Range Rover

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Semper Fi!
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Old March 16th, 2010, 08:44 PM
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Julien Dalbin
05 Tdi 90
Join Date: Mar 2005
Location: Dominican Republic
Posts: 1,884
This could be a good starting point:
" Eventually everything connects - people, ideas, objects. The quality of the connections is the key to quality per se. "
- Charles Eames
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