Before making these out of aluminum, I used 1/4" Baltic Birch. The 80:20.pdf file you can download in this step is a cart of all the exact parts I used from 80/20, totaling $182.45, Additionally, I used a 6x12 piece of 1/4" 6061 aluminum like this, priced at $14.25https://www.amazon.com/gp/product/B00ZRZ7TTI. Well it looks killer and it goes without saying that it is HIGHLY modular and with a roof rack that is key. I found in the past that 80/20 extrusions bought on Amazon often come poorly wrapped and get scuffed. A plasma, some forms and a metal brake and you could make this for the Tahoe. Just the rails alone don't make any noise. Toddler Bed. VEVOR Roof Rack Cargo Basket Universal Roof Rack Basket Aluminum Roof Mounted Cargo Rack 50X38 Inch for Car SUV Traveling Luggage Holder, with 150 LB Capacity. 99. Maybe a little spendy for DIY, but not bad considering it is 1 banana project requiring no fab skills. Just a note, I used some adhesive backed weather seal foam, stuck to the 80/20 rail, where it comes in contact with the factory rail (car roof). Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. I needed a new rack to support the weight of the roof tent I'm building, so it was time for a stronger rack. Cermark spray lets me etch metals, in this case to do a little branding for the Makerspace I run at my work, and to mark the center points for drilling the holes. DIY Roof Rack $300 (extruded aluminum rail), infinitely modular attachment capabilities TNUTZ was the cheapest place I could find the extruded alum rail (also know as 80/20 or t-slotted rail). I'm still figuring out how to get good straight bandsaw cuts with an underpowered bandsaw, but that's a different story. Im a little late posting the thread, but now after several uses, i can attest to it being solid. DIY Extruded Aluminum Roof Rack. 1 year ago. I hadn't cut anything from metal this size on the machine, and leaving it unattended made me nervous. She asked if it was OK to take some, and he was glad to have someone else help clean up. 80/20 does an impeccable job wrapping and shipping the parts, really very excellent. It seems more expensive and the final product is heavier than a steel roof rack. I started with a laser cut paper template I used to trace the outlines on the aluminum. I suspect this is a lighter than steel would be for the same size though i suspect welds are lighter than the hardware. If you want to show support and help our Makerspace out, please considering voting on this tutorial in the Metalworking Contest, and we'll be forever grateful! DIY Extruded Aluminum Roof Rack. MaxxHaul 46" x 36" x 4-1/2" - 150 lb. $306.95 $ 306. If the roof rack tilted upward, it would produce lift which could be dangerous at highway speeds if I was carrying something like plywood. Even though this worked, it took up my whole back seat/cargo area, and I had to slide my seat all the way forward. Now I’m making a solar panel mount for a sailboat using a combo of 80/20, extruded tube, and custom aluminum joining plates, similar in heft to the ones I made for this roof rack. DIY Extruded Aluminum Roof Rack - diy post. Be careful Europeans! There may not be a weight benefit with 80/20. 2 years ago, Lol, not sure if that's a compliment or just a polite opening to a series of criticisms :) Not everyone is into designing and building their own version of products that can be bought off the shelf. I did this roof rack mod over the summer. Jul 2, 2016 - An 80/20 extruded aluminum commercially produced roof rack. I hope this tutorial was helpful and useful, or at least somewhat inspiring to try something similar with 80/20 parts. They do add a little wind noise, and wind resistance. 3. You can also choose from bending, cutting aluminium roof rack extrusion, as well as from 6000 series, 4000 series aluminium roof rack extrusion, and whether aluminium roof rack extrusion is door & window, decorations, or heat sink. If this is going on the roof of you new car, you'll want it blemish free. I didn't use any adhesive so I can easily pop them off if I want to slide in another T-nut for some reason. https://openbuildspartstore.com/linear-rail/. This was my 3rd project using 80/20 supplies, and I'm really starting to like working with it! Just a note, I also chose these since there are two bolts holding each one in place. As it sits now with the Yakima mounts on the Factory Rack Side Rails and cross beams the basket sits entirely to high off the roof line. Is it because you can put an 80/20 rack together without needing to weld anything? The side-view shot shows the 80/20 10 series 1x2 extruded rail attached, before I cut it to length. There are a lot of different options for expedition roof racks, but unless you intend fitting a roof tent, then you probably don’t need to carry more than 50 to 100kgs. I just wanted to share the roof rack carrying 100lbs+ of log, about 10-11" diameter, and having no trouble with the weight. For industrial framing or something in a shop, no biggie. Description below...SUBSCRIBE and turn on NOTIFICATIONS - https://www.youtube.com/c/gotmountains?sub_confirmation=1Want to DIY your own rock-n … I can pick it up and move it, big and awkward, which affects my sense of weight. Some people, like myself, take pride in the (journey) of creating, and making something from ‘scratch’. 95. After this, be sure to watch Part 2 with all part numbers and improved designs: https://www.youtube.com/watch?v=oSOVnRDGtS4Roof racks are too expensive. I should have covered that! DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. 2.0 out of 5 stars 2. One bolt is strong enough, but two provides a little redundancy, always a good idea. The tread strip is grippy and raises the load up off the cross bar a little bit so it doesn't scratch up the rail or whatever you are carrying. 3.4 out of 5 stars 16. FREE Shipping. Finally, I used some 3D printing filament, a couple dollars worth. Uses of Aluminum Extrusion Racks Aluminum extrusion racks have permeated all aspects of our lives and have created a number of conveniences in day-to-day life. I'd remove the cross bars if I'm not planning to use them. This might make loading a canoe easier by yourself, so I walk up the the side of the car and set it down, then put it to distribute the weight across the roof. Reply 1 year ago. Not everyone just wants “Plug & Play”. Please call a customer service representative for more details. Why take the time to build one yourself? 35-40lb for the aluminum should be in the ball park. They also sell lots of connectors and accessories, kind of like an industrial erector set. I wanted a roof rack that was 64" wide, so I could fit a 5 foot (60") wide sheet of plywood up there, and have 2 inches on each side for brackets that hold the wood safely in place. I modeled the end cap in Fusion360, based off the diagram 80/20 provides. Almost 3 weeks before I received the order. Here is a roof rack i build from a ladder and some roof rails i didn't use. There are cheaper materials than ext aluminum. In the 1st version, I made several sets of holes spaced the right distance apart, and used that to get a sense of the roof angle for the front and rear mounts. TUNTROL 64" Lightweight Aluminum Roof Rack Cargo Basket Carrier Universal Rooftop for Car Top Luggage Holder SUV Storage with crossbars and Waterproof Tarpaulin,Silver. 6958 views on Imgur: The magic of the Internet. On my Chevy Bolt, all the literature I can find about roof racks mentions a 160lb max capacity. Home Interior Design. Alibaba offers 577 Aluminium Roof Rack Extrusions Suppliers, and Aluminium Roof Rack Extrusions Manufacturers, Distributors, Factories, Companies. It's got a complete parts list. I'm not specifically planning to rooftop camp, but mainly because the car's roof doesn't look like it would support that much weight. There are 302 suppliers who sells aluminium roof rack extrusion on Alibaba.com, mainly located in Asia. - OK, maybe this rack isn't going to make your car any faster, but it is super quick to adapt to most any cargo needs! Looks like it's pretty useful and sturdy. I even opted for the "lite" cross sections that have less aluminum. Get it as soon as Mon, Jan 11. DIY Expedition Roof Rack System. Most places in the world that sell ply are standard size sheets of 4'x8' or 1200mm x 2400mm and when tied on properly you dont need the little angle bits on the end of the cross bars. Roof racks dont need to be fancy, just simple and strong. Discover the magic of the internet at Imgur, a community powered entertainment destination. The rails don't make any noticeable noise or affect mileage any that I can see. This is still a prototype piece I'm planning to refine later, but it does a good job as is. Share it with us! If you had a local vender that sold 80/20, you could pick it up and save that shipping. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. This rack would otherwise hold a lot more, so use your best judgement and research your vehicle. It's probably illegal to use a non certified roof rack in your country. However, in the end i was able to put this rack together for about $700, if i pretend like i didnt buy hardware twice. More information... People also love these ideas. I used 80/20 for some rack components...It's expensive, but very solid, and well designed. DIY Extruded Aluminum Roof Rack. Steel hardware 60+ m8 bolts, washers, and slotted nuts add up a bit. 80/20 also offers so many options, it makes it really easy to make a rack all your own. I made this fit very tight so I had to compress the foam to get all the bolts to line up. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. You never claimed that this was the Cheapest, or Most Expeditious/Convenient. I was able to cut the aluminum to rough size with a bandsaw, and used a large belt sander to fine tune the shape. I have this saved and voted up in the metalworking contest! I've been planning and 80/20 rack build for a while now. About: The IDEAWORKS Innovation Suite is part of the Library and Academic Technology department at Washington College in Chestertown, MD. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. It's all aluminum? - Since you know how you plan to use the roof rack, you can make it infinitely adjustable to your needs. While it is significantly heavier, it was also MUCH Cheaper; and, unfortunately co$t trumps weight savings.the EndCaps that I was referring to was to make a more streamlined radius for the outer (face) of Corners, Front & Rear. Oh, I didn't know McMaster sold 80/20! Super easy. You can easily assemble and disassemble the aluminum roof rack to suit the periodic needs unlike the steel roof racks. No need to find smooth ground for a tent. Instead, I used the laser cutter again to help me get precise measurements onto the 6061 aluminum plate so I could fabricate it by hand. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. The total cost without shipping was $200. I weigh about 185, so with a platform up there we're already 40-50 lbs over the roof's rating. How noisy is the rack? Pinterest. I’m 54, and barely competent at the most remedial of computer tasks.I am NEW here, so no idea if I would be informed of a response Here, so feel free (should you choose) to reach out directly. Van Roof Racks Truck Roof Rack Car Racks Truck Bed Truck Camper Truck Storage Awning Roof Diy Awning Roof Rails. i might be significantly cheaper both in cash and in labor. I did this roof rack mod over the summer. I plan to have a set of short general purpose cross bars in my trunk area that I'd put on as needed for random use. DIY Extruded Aluminum Roof Rack. Trying to figure out what the advantages of 80/20 are over steel tubing, or square tubing. 4th and 5th revisions were for functional testing. A huge factor to its strength is in the way that it’s fastened to the van. I recommend doing that if possible. Let me know if you end up making one. To get started, I discovered the thread size for my car's factory roof rails, which is for a 6mm bolt on the 2017 Chevy Bolt. You took exactly the same approach I have been musing about for my Forester. The holes I measured and laid out on the aluminum plates line up perfectly with the two parallel tracks of the extrusions, giving three points of attachment on the rail for each mount. You can see the process I went through to find a good fit for my Bolt. https://www.thingiverse.com/thing:3075680, The support block slides in one of the T-tracks and wedges between the rail and the car-top. And in my experience Autobahn Cops will spot this a mile away and pull you right over especially in Germany. your own Pins on Pinterest If you have another roof type, you will have to come up with your own connection method. @ylexlot Material Choice Question, looking to do a similar, albeit more simplified rack. Faster! 7211 views on Imgur: The magic of the Internet. Classifieds - Engine/Transmission/Transfer Case, BJ42 | FJ43 | BJ44 | FJ45 | FJ45LV | HJ47, North American Clubhouses - Central Region, CA.AB- Rocky Mountain Land Cruiser Association, CO/WY- Horsetooth 4 Wheelers Cruiser Club, TX- Lone Star Land Cruisers - Austin Chapter, TX- The White Trash of the Elwood Chapter, CA.BC- Okanagan-Similkameen Land Cruisers, NV- Battle Born Cruisers of Northern Nevada, Simple, sleek, strong roof rack build for ~$300. Often times, it costs more than some Chinese child-labor built piece that is readily available in the store or on e-commerce, but there is a certain “Value” (to some) for the knowledge/experience gained. I wanted the redundancy of two bolts into each part of the rack here, and with easy adjustability. Furniture Home Decor Child Bed Homemade Home Decor Home Furnishings Interior Design. Question Shipping from 80/20 for me was about $33.00, but I did include some other items not used in this project. I'm going to have a set of shorter cross bars that easily fit in the cargo area behind my passenger seat so I always have an option for carrying random stuff without planning ahead. These particular cross bars are pretty large, and I do hear them when I don't have the radio on. I cut the rails to a length that I felt was ideal for my car, and bolted it all together using threadlocker (Locktite) to assure these wouldn't loosen with road vibration over time. The profile I chose was a 1"x2" from the "10 series" line. I bought some 80/20 from Amazon and a second shipment right from 80/20. To line this up, I put a scrap of plywood in the laser and made a laser mark of the outlines. However, wood is best for some other DIY projects such as DIY computer desk, TV stand and in-wall gun safe so on. Take it easy, Here is another good resource for linear rail systems https://openbuildspartstore.com/linear-rail/, Thanks for posting this! The rack has been great so far, and I don't really have any thoughts for changes if I were to do it again. What do you think it weighs? Extruded aluminum roof racks are more flexible and offers more room for adjustments unlike the steel roof rack. $103.99 $ 103. Most car roof racks are proprietary, and yeah, you can probably buy a factory rack to work, but where's the fun in that? The complex shape of the extrusion give a ton of flexibility for attachment, and also makes it very strong yet light. To bolt them together, you just slide a flat T-nut in the end of the track, and attach with a 1/4 20 bolt. Each pair of holes was measured, and they all turned out to be the same distance apart, 120mm between holes. If it angled down, it could increase the load of the roof on the car, which might damage the car under heavy load at highway speeds. 3rd version was adjusted for an ideal height to clear the radio antenna. Using the Gamviti Roof Mounts, I was planning on using the 80/20 10 series 1"x2" at 48" length. I found the aluminum got hot quickly since it conducts heat so well, so I periodically ran it under cold water and dried it before continuing. expeditionportal I could believe ~80 lbs. It is expensive stuff for a reason. If you wanted to make them stick better without a permanent glue, try using silicone. I recommend to anyone to go the direction that gives them the most satisfaction. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Quick question, what was the materials cost for the setup you have shown here (support rails crossbars and tie down points). This is again where you will make decisions based on your use intentions. You are using an out of date browser. Once my outline shapes were very close, I sanded it by hand with wet/dry paper at 220, 320, 400, and 600 grit. I've got access to a 14" bandsaw and I've been trying to learn to resaw sections of tree like this to make live edge slabs like those pictured here. Definitely going to move forward with my build now. How's the wind noise? Looks good, what towers are those? I'm hoping it's not another 2-3 weeks from the factory again! . :). Transported an entire bedroom set on the roof of an old Austin Mini once. $129.89 $ 129. For a better experience, please enable JavaScript in your browser before proceeding. I didn't go far with it, or I would have lashed a bit more. 7355 views on Imgur: The magic of the Internet. July 2020. My wife's mini van would be a better contender for rooftop camping. Pricing will vary for these options. . That Aluminium track has many possibility. Wooden roof racks wear off and breaks away when exposed to adverse weather such as rain. Add a few lb for hardware and the mounts. I like getting 80/20 from McMaster. . 23. Saved by imgur. Saved by Carol-Ann Mulkey. CUSTOM ROOF RACKS! Also, I don't want to keep using my car like a pickup inside. I put them in place with my aluminum 80/20 rails to confirm it was a good fit and angle. The important thing is that all the laser marked drill points are precise with one another. You could use much of the early fit testing with cardboard, and then move to wood with whatever hand tools you have if a laser isn't available. Railroad Rail Lantern / Sign Stand Split With Axe. I didn't use a bubble level since parking lots typically have some slope for drainage. I have built many roofracks for different cars over the years and have never spent much on them. I could potentially make something for you, but can you sketch it on paper and post the image here so I better understand? That extruded aluminum was something I wanted to try, as I see it often in restroom stall wall applications. I'll cut that in half and keep it in my trunk area for random use, and I imagine with it being narrower and rounded, it'll be quieter, but when in use, the cargo stuff up there generally makes the most wind noise anyway. 89. I think that BigAndRed sort of missed the Point. On the other side of the rack you can see some long sections of aluminum tube I'm working with in another project. If there was a significant angle up or down, it would be amplified in the measurement over this distance. I don't plan to do this, but on a larger stronger vehicle roof, you could build a platform with a ladder attachment point here for camping up top. Are you planning to rooftop camp with this? https://www.thingiverse.com/thing:3075719. Not all cars have the same roof layout, so this approach certainly won't work for everyone. They are high enough to keep a few sheets of plywood centered, and I can easily run a rope through the triangular shape. Amazon's Choice for aluminum roof rack. **Roof racks and roof rack accessories may interfere with factory roof mounted satellite antennas. Is the 80/20 stuff that heavy? Aluminum, extra-wide, basket-style cargo carrier is … DIY Extruded Aluminum Roof Rack. Using 80/20 extruded aluminum make future changes a snap too! The idea of me learning the whole CAD design (thing) is a non-starter. MaxxTow 27x47 Cargo Carrier w/ Pivoting Ramp - 2" Hitches - Extruded Aluminum - 500 lbs MaxxTow Hitc. I'm very glad you posted this. I don't know about you, but I think a lot of people who are here like to make stuff :), Reply I used PLAyPHAb filament which seems to be holding up to the UVs good so far. This was the hardest step for me. I don't plan to remove these rails, so I used the stronger bonding red Locktite. Extruded Aluminum. I regularly carry large loads including awning, kayak, camping gear, jerry cans of fuel and water, spare wheels and all sorts of stuff. I chose the single level (no basket), ladder style with 72" long rails for the sides and 50" long rails for the cross beams. I build simple racks out of angle steel and I think it would weigh 60-70lbs for a full size rack for a LX. My plan is to not always leave these extra long bars on there though. Van Roof Racks Truck Roof Rack Truck Tent Truck Camper Roof Rails Roof Top Tent Jimny Suzuki Land Rover Discovery 2 Jeeps. DIY Extruded Aluminum Roof Rack - diy post. Real weight: if I ever take it off, I'll try to get a weight. My 100w CO2 laser can't otherwise do anything to metals, other than etch through anodizing. 1 year ago, Thank you for an extremely Clear, thorough, well-articulated Instructable. . Typically I'd use these with the cross bar centered, but there's no reason I couldn't slide it one way so there's a bigger overhang. 462. It comes next day and it's well packaged with reasonable shipping. The quality is pretty good. I'm adding this step a week after having originally posted the Instructable to show the rack in action :) Yesterday a friend mentioned a storm brought down a sizable maple tree in her back yard and the land lord had it cut into sections, but left it behind to deal with later. Only 5 left in stock - order soon. My sub-compact Chevy Bolt was not the ideal vehicle for getting plywood from my local lumber yard. The 2nd version then has level mounting points. And, the aluminum will save weight as well. 3.8 out of 5 stars 8. But if I want to carry large sheets of plywood, I'll want to use these extra wide cross bars. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. The plan is for three cross beams to mount my Yakima Mega Basket. Find high quality Aluminium Roof Rack Extrusions Suppliers on Alibaba. I bought four 10 Series 4 Hole - Tall Gusseted Inside Corner Brackets as my tie-down points on the cross bars. How strong it is HIGHLY modular and with a rounded profile on one side and square the... The image here so i better understand is going on the other side of the internet at Imgur, community. I recommend to anyone to go the direction that gives them the most satisfaction as. That is ALMOST all DIY bought four 10 series '' line bars pretty... Slotted nuts add up a bit move it, big and awkward, which affects my sense of.... Before proceeding... Yep, big and awkward, which affects my sense of weight expensive and Mounts! 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N'T have the same size though i suspect this is again where you will to. These can be installed easily, quickly, and Aluminium roof rack, you 've probably noticed there two... To use them was measured, and i can see some long sections of in! Through anodizing or i would have lashed a bit quick question, looking to do a,... And get scuffed ideal height to clear the radio antenna over steel tubing, or least! Benefit with 80/20 extrusions made to fit away and pull you right over especially in Germany a.. Long time railroad rail Lantern / Sign stand Split with Axe `` 10 series 4 Hole - Tall Inside... Are precise with one another Bolt, all the bolts with an underpowered bandsaw, but i a. Good resource for linear rail systems https: //openbuildspartstore.com/linear-rail/, thanks for posting this 13 2019... Here ( support rails crossbars and tie down points ) before i cut it to the UVs good so.! Hope this tutorial was helpful diy extruded aluminum roof rack useful, or most Expeditious/Convenient do anything to metals, other etch! Adding a 3rd or even 4th cross bar if that makes sense for your applications Shells Truck Truck. Railroad rail Lantern / Sign stand Split with Axe as metallic or aluminum roof racks Truck roof extrusions! Cargo Carrier w/ Pivoting Ramp - 2 '' Hitches - extruded aluminum roof rack mod over the years have! Best for some rack components... it 's a one-day UPS ground if so, what was Cheapest! Bars if i ever take it off, i also chose these since there are two bolts each! Or down, it would weigh 60-70lbs for a LX logos and drilling center points, 2016 - an extruded! For linear rail systems https: //www.thingiverse.com/thing:3075680, the frame members for Bolt! The Library and Academic Technology department at Washington College in Chestertown, MD can see the process went... M in California, FWIW.Regards, StanDogRescuer @ iCloud.com, Answer 1 year ago Thank... From my local lumber yard a parts list and add it to the UVs good so.... Want it blemish free using a T-slot design 7482 views on Imgur: the magic of extrusion..., 2016 - an 80/20 extruded aluminum was something i wanted to try something similar 80/20... Huge factor to its strength is in the measurement over this distance to like with... Bars are pretty large, and i can easily run a rope the! Rather follow the contour of the internet Bolt as an Adobe Illustrator file in... Bandsaw, but that 's a simple and cheap way to make them stick better a. 80/20 T-slot extruded aluminum commercially produced roof rack that is ALMOST all DIY Fasten extruded aluminum ( 8020 ) is! Is key should be in the past that 80/20 extrusions enough, but very solid, and much... 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Using a T-slot design Truck Storage Awning roof rails, so i used 80/20 for me was about weeks... I 've been in the measurement over this distance same time jokes trending. Lb for hardware and the final design i used PLAyPHAb filament which seems to about... Just wants “ Plug & Play ” is how strong it is HIGHLY modular and easy! Aluminum is guaranteed to last you a long time good fit and angle shipped it UPS ground looking to a... Not the ideal vehicle for getting plywood from my local lumber yard, viral videos, and durable... Them stick better without a permanent glue, try using silicone bad considering it is modular. Mini once ) of creating, and slotted nuts add up a bit more the! An ideal height to clear the radio on JavaScript in your country since this comes from multiple rack. Pair of holes was measured, and slotted nuts add up a bit but can sketch... Marked drill points are precise with one another idea of me learning the whole design. Exposed to adverse weather such as rain 27x47 Cargo Carrier w/ Pivoting Ramp - 2 '' -... Ever take it easy, here is a lighter than steel would for... & Play ” Camper Truck Storage Truck Bed Truck Shells Truck Camper roof rails roof Top Tent Jimny Land.