Roof rack construction

[Forrest747]

Has anyone built thier own roof rack? I am looking at the cost and for what I want and thinking building my own the right option for me. i want to have telescoping poles that come out to have the side tent drop down. I could also put some things like table or chairs. maybe cot for older kids.

I am thinking of using just electrical conduit and will paint.

[len19070]

I built a few about 4-5 years ago using Electrical Conduit (painted). Very easy to fabricate...and Cheap! I don't think I had $15 in each one (the Cedar & Varnish costs the most)






Happy Trails

Len

[KCStudly]

Those are really nice racks. Good job!

[225]

Those are really nice racks. Good job!

I same the same thing when I eat at Hooter's.


I plan on having one on my TD.

[bobhenry]

This one was off of a jeep wagoneer. Was very simple to modify and mount.



alas no pull out privacy curtain though

[Lancie49]

I like that conduit idea

Did you set up a jig for the bending ?
I assume a heatgun to soften the pipe ?

What sort of weight would those rack carry ?


Lance

[danlott]

Do you have to do anything special when welding the conduit? Does the galvanized metal cause problems when welding?

Dan

[Forrest747]

Do you have to do anything special when welding the conduit? Does the galvanized metal cause problems when welding?

Dan

Yes you can weld it. Alot of people grind off the galvanize coating then weld.

[len19070]

I used 1/2" EMT (Electrical Metal Tubing) on one (Pac-Man) and 3/4" on the other (SlumberCoach). I liked the 3/4" better.

Yes it is Galvanized and that can cause some respiratory problems when welding.....but a fan blowing across your welding area cures all that.

I used an EMT bender, a $2 yard sale find or $20 at Home Depot new, a grinder to cut the scallops in the cross members and my Trusty $90 Harbor Freight Welder.

Easy Peasy and lots of fun to do.

What sort of weight would those rack carry ? Lance

I carried 2 kayaks on it sometimes and 75 to 100lbs of gear on it others....never a problem.

So simple a Carpenter can do it.

Happy Trails

Len

[Mikka]

I used 1/2" EMT (Electrical Metal Tubing) on one (Pac-Man) and 3/4" on the other (SlumberCoach). I liked the 3/4" better.

Yes it is Galvanized and that can cause some respiratory problems when welding.....but a fan blowing across your welding area cures all that.

I used an EMT bender, a $2 yard sale find or $20 at Home Depot new, a grinder to cut the scallops in the cross members and my Trusty $90 Harbor Freight Welder.

Easy Peasy and lots of fun to do.

What sort of weight would those rack carry ? Lance

I carried 2 kayaks on it sometimes and 75 to 100lbs of gear on it others....never a problem.


So simple a Carpenter can do it.

Happy Trails

Len

You can achieve flawless scallops with a hole saw the size of the tube, a drill press and a vice. Perfect every time when you start cutting dead center on the tube

[len19070]

You can achieve flawless scallops with a hole saw the size of the tube, a drill press and a vice. Perfect every time when you start cutting dead center on the tube

Yes, and on larger diameter pipe that may be a viable option.

However!

On a 3/4" pipe by the time the "curved" excess gets jammed in the hole saw...and the time, and effort it takes to clear out the excess to get ready for the next cut.... some times 30-35 times a Rack.

Its easier to grind them.

One of those theory vs. practice things.

Happy Trails

Len

[CarlLaFong]

^^^^^^^^^^^Yep, you can cope a piece of EMT with a rat tail file in less time than it takes to fool around with the holesaw.
I did a bunch of pieces for a project a few years ago. I made a hardwood jig. It had a hole that the tube slid into and a half round groove running perpendicular to the hole. Stick the tube in until it flushes with the top of the groove and file away. I did split the jig with a groove running parallel with the hole so it would squeeze down and hold the tube in place when clamped in the vise

[KCStudly]

'Bang it in the mill and hit it with the same size cutter' is another option.

However, I do tend to use hand files more than most fabricators I know. I have more control (i.e. takes longer to make a mistake) that way, and I get a higher self sense of craftsmanship that way.

[Juneaudave]

I really liked Len's roof rack and did a version of it for my trailer...here is the webpage link with some of the construction details. It turned out pretty strong, and I carry everything from firewood to drybags filled with camp stuff...but I haven't ever put my canoe on it though. The hole in the middle is where my vent opens.

[CarlLaFong]

'Bang it in the mill and hit it with the same size cutter' is another option.

Sure, or you can use your waterjet or your laser cutter. Of course, you'll want to run it through your X-ray machine after you weld it with your electron beam welder. Afterwards you can run it through your plating system to give it a nice shine and protect it from the elements
I'm lucky enough to have a mill, though I don't have any of the other stuff.................yet. I think most of the folks on this board are working with less sophisticated tools