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  #1  
Old June 3rd, 2012, 01:58 PM
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Roof Rack build

I'm building a rack for my 90.

I'm using 2x1 14awg rect tubing for the permiter (on edge obviously), total of 10 gutter mounts made from 2"x 3/16" flat bar. Based on my calculations i'm at about 50lbs right now.

The rack is going to be flat (no basket), and I would like to keep everything flush. I'm a bit stumped on what to do for the floor framing

Should I use Aluminum or steel? What I was thinking was put another 2x1 rect tube as a spine down the middle, then make a notch (and weld it closed) for a 1x1 Alumin Sq Tube to sit in about every 8" The span from side to spine will be about 24". I'm worried thats too big of span for 1.x1 alumn tubing (.120wall) to support my weight). Further more I dont plan on putting a floor down (i want to be able to hook a tie down strap anywhere), so each cross bar will stand on its own.

I'm worried about using steel (although it would be ALOT less work), as its going to be 65lbs worth of cross bar vs 25lbs w/ aluminum

I was hoping to keep this entire rack under 100;bs. I want it to support 350lbs while driving and also my weight if i need to climb up there. Ideally I'll be putting bulky but light items up there (cases with clothing, tents etc) but I'll probably have 2-4 jerry cans up there as well (possibly 160lbs in those alone).
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  #2  
Old June 3rd, 2012, 02:18 PM
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Keep in mind if you ever go with a rooftop tent setup you'll want it support the weight of the tent and at least 2 individuals.
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  #3  
Old June 3rd, 2012, 02:51 PM
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Good point. But I think the 350lbs goal would have that covered
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  #4  
Old June 3rd, 2012, 02:59 PM
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ARB tent for example weighs in at 150-ish I think....
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  #5  
Old June 3rd, 2012, 03:12 PM
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Wow didn't think a tent would be that much. Altough I doubt I'll ever drop the coin on ARB roof tent anyways....
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  #6  
Old June 3rd, 2012, 03:32 PM
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150 pounds for a tent. Amazing.
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  #7  
Old June 3rd, 2012, 03:58 PM
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Quote:
Originally Posted by chris snell
150 pounds for a tent. Amazing.
That's why I ditched mine.
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  #8  
Old June 3rd, 2012, 04:56 PM
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Check out some sites on Front Runner and Hannibal roof racks to get some ideas. Both of they'res are flat with unique add on ideas. I especially like the Front Runners slotted slats to tie things down to.
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  #9  
Old June 3rd, 2012, 05:11 PM
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I did look at the front runners, i just wish had a tig and the ability weld Al, if I did I'd be copying there design exactly lol
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Old June 3rd, 2012, 05:17 PM
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Adrian, what kind of welder do you have? you might be able to get a spool gun
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  #11  
Old June 3rd, 2012, 05:43 PM
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Yea I looked into it, and it could be done I have a Lincoln pro Mig 140. But they aren't cheap (200 or so) and I think its a long learning curve. I plan on trying it, but I'd like to get this done well before I learn that skil..

That and I already have a good amount of this done already, just need to figure out if I should do all steel and have a rack thats about 115lbs, or mix and match and have a rack thats just under 100lbs
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Old June 3rd, 2012, 05:54 PM
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you can always just rig the mig with aluminum take like a broom handle tape it to the torches cable so it stays straight. and than you'll be able to use a spool of aluminum also you need 100% argon and need to swap the polarity wires in the mig with takes a few mins.
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Old June 3rd, 2012, 05:58 PM
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I have a bottle of 100% Argon, Maybe I'll give it a shot later tonight and see what happens. if I have decent results maybe I'll fork up the money for a spool gun.
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Old June 3rd, 2012, 06:09 PM
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yea it will be worth it
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  #15  
Old June 3rd, 2012, 06:46 PM
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STEEP learning curve going to aluminum MIG. Unless you are an experienced welder, you'll either burn through your material or glob it up. I ditched my spool gun in favor of a TIG for aluminum welding.
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  #16  
Old June 3rd, 2012, 06:59 PM
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Just gave the broomstick trick a try


Failed miserably.

If I use aluminum it will bolted/ fastened in place

So do you think 1x1 al tubing .120 wall i will hold175lbs over a 14" span

What about a 26" span
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Old June 3rd, 2012, 07:06 PM
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14'' span, most likely. 26'' span it may flex a little, but it will hold.
the broom stick trick didnt work? what specifically did you fail on? blew right threw it or boggered up?
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  #18  
Old June 3rd, 2012, 07:41 PM
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Adrian - I have that TIG box that you can use. Not sure what amps it goes up to but should do decent sized walled aluminum. It's a Lincoln Precision 185.

Actually Welder Mike said he'd stop by one day after work and give me some pointers/lessons/tips if you want to stop over. Dude is a wizard on the torch. Rode trails (bikes) with him today and he gave me a few things to work on like torch angle. TIG is a bish - he said it's fustrating but you just have to do a little everyday.

BTW, rack was looking good yesterday - I say go for the aluminum floor - one less thing to powder and worry about rust.
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Old June 3rd, 2012, 07:46 PM
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Have you bent the outside frame yet, are you rounding the corners or just making them square? I am planning to build a steel Hannibal knock off myself but the more planning i do the more I am thinking just forking out the cash for the real deal may be the way to go considering the amount of work that is going to have to go into it.

Jason
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  #20  
Old June 3rd, 2012, 08:31 PM
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As soon as I put it against some AL it would jam up between the cable and the spool itself

The frame is all done, along with the risers welded on. I'm going to put two splines down the middle same 2x1 rect 14awg tubing I'm going to take the time to notch each spine and outer rail and lay AL cross bars in. Gonna take some time, but I think the AL cross bars on a matte black powder coated frame will look cool. Plus the longer I spend working on this the less money I'll spend doing other projects lol


Don, let me know when he comes by I'll deff attend the schooling lol
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