Roof rack build

[Primosboy]

Quick and easy roof rack build. Wanted a larger rack for overlanding and i did not want it to go on the stock cross bars. I don't like how high it would have sat off the roof. Did it all for free with spare material but I priced it out at $150. Hoops are made from 3/4 emt. Light weight but strong when you have enough contact points. Cross bars are imc which is slightly thicker but still lightweight. I used 1/4" plate for the uprights connecting the hoops. Probably little overkill but it's what I had lying around. Some heavy expanded metal for the bottom. That's the most expensive part. Home depot sells 4 packs of d rings I used to extra tie down points. The tricky part was the mounts. I used 6 pieces per foot using 1/8" bar and 1/4". Some light gauge steel for the logo that covers my crappy offset bends. Finished with rattle can bedliner. Rack sits about 2 inches off the roof and it's very strong. I can jump up and down on it no sweat.

 

[franklin2]

Be careful welding on electrical conduit. It is galvanized. Should be ok with good ventilation from the outside.


OSHA Requirements for Welding Galvanized Steel

Galvanized steel is coated by zinc, a metal that when heated and inhaled, can cause fever, nausea, and coughing, known as metal fume fever. When welding with a zinc-bearing base or filler metal, OSHA requires employers to provide general or local exhaust ventilation systems.

 

[Uncle Gump]

Those rail mounts do look a bit tricky... lots of work to get four alike.

I have the factory rails on my Bronco II... was hoping there would be something off the shelf that would work. I really haven't looked very hard for options.

If I couldn't find something suitable... I figured I would just use flat steel that would slide into the channel... weld tabs to that to mount a crossbar or roof rack... drill holes in the flat steel and weld nuts to it so a bolt could lock it to the rail.

That project is down the to do list a ways...

Nice job overall... thanks for sharing.

 

[Jazzer]

Sweet.

-Jazzer

 

[Primosboy]

Those rail mounts do look a bit tricky... lots of work to get four alike.

I have the factory rails on my Bronco II... was hoping there would be something off the shelf that would work. I really haven't looked very hard for options.

If I couldn't find something suitable... I figured I would just use flat steel that would slide into the channel... weld tabs to that to mount a crossbar or roof rack... drill holes in the flat steel and weld nuts to it so a bolt could lock it to the rail.

That project is down the to do list a ways...

Nice job overall... thanks for sharing.

That sounds like an easier option actually ha.

 

[Primosboy]

Be careful welding on electrical conduit. It is galvanized. Should be ok with good ventilation from the outside.


OSHA Requirements for Welding Galvanized Steel

Galvanized steel is coated by zinc, a metal that when heated and inhaled, can cause fever, nausea, and coughing, known as metal fume fever. When welding with a zinc-bearing base or filler metal, OSHA requires employers to provide general or local exhaust ventilation systems.

Yeah I worked for a welding shop for a few years. They claim drinking milk beforehand lines your throat and protects you. I've never gotten sick so must work lol.

 

[Shran]

Good work - I used the factory "tracks" on my roof to mount my rack as well. I took two pieces of 1/2" square tubing and made my own cross bars that bolt down to the little tie down nut plate things and then used hose clamps to secure the rack to the square tube. Kept the rack really low which was my goal.

I have heard about the milk trick, never tried it, I just make sure I am welding galvanized in a very well ventilated area and never have my head right over the work.