Let me know if you end up making one. There may not be a weight benefit with 80/20. I didn't use a bubble level since parking lots typically have some slope for drainage. I could believe ~80 lbs. To attach the cross bars to the roof rails, I used four 10 Series 4 Hole - Wide Inside Corner Brackets. Quick question, what was the materials cost for the setup you have shown here (support rails crossbars and tie down points). Im a little late posting the thread, but now after several uses, i can attest to it being solid. https://www.thingiverse.com/thing:3075719, 10 Series 4 Hole - Tall Gusseted Inside Corner Brackets, 10 Series 4 Hole - Wide Inside Corner Brackets, flat covers to the ends of the cross bars, considering voting on this tutorial in the Metalworking Contest, https://www.amazon.com/gp/product/B00ZRZ7TTI, How to Make Charcuterie Boards Using Clear Acrylic Templates. Description below...SUBSCRIBE and turn on NOTIFICATIONS - https://www.youtube.com/c/gotmountains?sub_confirmation=1Want to DIY your own rock-n … TUNTROL 64" Lightweight Aluminum Roof Rack Cargo Basket Carrier Universal Rooftop for Car Top Luggage Holder SUV Storage with crossbars and Waterproof Tarpaulin,Silver. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Pinterest. I recommend doing that if possible. 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. Plus adding on to it is easy. DIY Extruded Aluminum Roof Rack. I build simple racks out of angle steel and I think it would weigh 60-70lbs for a full size rack for a LX. Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. I put them in place with my aluminum 80/20 rails to confirm it was a good fit and angle. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. A plasma, some forms and a metal brake and you could make this for the Tahoe. This example is for any cars with factory attachment points already available. If you wanted to make them stick better without a permanent glue, try using silicone. I'm hoping it's not another 2-3 weeks from the factory again! 7482 views on Imgur: The magic of the Internet. I bought four 10 Series 4 Hole - Tall Gusseted Inside Corner Brackets as my tie-down points on the cross bars. Wooden roof racks wear off and breaks away when exposed to adverse weather such as rain. Discover (and save!) It has to be less than 80 lbs. 3rd version was adjusted for an ideal height to clear the radio antenna. I have access to a low-end CNC router, but it was going to be about 80 hours of cutting if I tried that. I just wanted to share the roof rack carrying 100lbs+ of log, about 10-11" diameter, and having no trouble with the weight. Thanks. 35-40lb for the aluminum should be in the ball park. 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. Trying to figure out what the advantages of 80/20 are over steel tubing, or square tubing. About: The IDEAWORKS Innovation Suite is part of the Library and Academic Technology department at Washington College in Chestertown, MD. 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. 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. Using the Gamviti Roof Mounts, I was planning on using the 80/20 10 series 1"x2" at 48" length. 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. My 100w CO2 laser can't otherwise do anything to metals, other than etch through anodizing. 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! I don't know about you, but I think a lot of people who are here like to make stuff :), Reply I wanted the redundancy of two bolts into each part of the rack here, and with easy adjustability. It may not display this or other websites correctly. I'd love to see other people's adaptations! Today. 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. This helps transfer the load of the rack to the car, and doesn't put all the weight on the bolts, since they are taking a sheer load. They are high enough to keep a few sheets of plywood centered, and I can easily run a rope through the triangular shape. All I need to do to adjust them is loosen the bolts with an allen key, slide, and re-tighten. For your $200 you could have bought an off the shelf, name brand rack that connect directly to the rails on your car in a few minutes. DIY Extruded Aluminum Roof Rack - diy post. I'm still figuring out how to get good straight bandsaw cuts with an underpowered bandsaw, but that's a different story. Be careful Europeans! The bars are at face height. There are 302 suppliers who sells aluminium roof rack extrusion on Alibaba.com, mainly located in Asia. I've got access to a 14" bandsaw and I've been trying to learn to resaw sections of tree like this to make live edge slabs like those pictured here. 6958 views on Imgur: The magic of the Internet. The important thing is that all the laser marked drill points are precise with one another. If the roof rack tilted upward, it would produce lift which could be dangerous at highway speeds if I was carrying something like plywood. Custom roof rack options include an open front rack, open rear, non-standard slat spacing, and a higher profile. Discover the magic of the internet at Imgur, a community powered entertainment destination. Is it because you can put an 80/20 rack together without needing to weld anything? Now I’m making a solar panel mount for a sailboat using a combo of 80/20, extruded tube, and custom aluminum joining plates, similar in heft to the ones I made for this roof rack. The rails don't make any noticeable noise or affect mileage any that I can see. Using specs online, the frame members for my rack should weigh in at a little less than 40 lb. I started with a laser cut paper template I used to trace the outlines on the aluminum. I've been planning and 80/20 rack build for a while now. I weigh about 185, so with a platform up there we're already 40-50 lbs over the roof's rating. While it is significantly heavier, it was also MUCH Cheaper; and, unfortunately co$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. This gave the surfaces a nice smooth and clean look. Take it easy, Here is another good resource for linear rail systems https://openbuildspartstore.com/linear-rail/, Thanks for posting this! Van Roof Racks Truck Roof Rack Car Racks Truck Bed Truck Camper Truck Storage Awning Roof Diy Awning Roof Rails. I did this roof rack mod over the summer. 1 year ago, Thank you for an extremely Clear, thorough, well-articulated Instructable. These particular cross bars are pretty large, and I do hear them when I don't have the radio on. Faster! I hadn't cut anything from metal this size on the machine, and leaving it unattended made me nervous. 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. Only 17 left in stock - order soon. Definitely going to move forward with my build now. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Extruded aluminum roof racks are more flexible and offers more room for adjustments unlike the steel roof rack. 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. Ha ha there is A LOT of aluminum in 80/20 too. Also, I don't want to keep using my car like a pickup inside. Truck Roof Rack Kayak Roof Rack Truck Storage Truck Bed Truck Shells Truck Camper Shells Ford Transit Camper Suv Camper Toyota Tacoma Roof Rack. I hope this tutorial was helpful and useful, or at least somewhat inspiring to try something similar with 80/20 parts. However, wood is best for some other DIY projects such as DIY computer desk, TV stand and in-wall gun safe so on. I'll make a parts list and add it to the instructable. I don't plan to remove these rails, so I used the stronger bonding red Locktite. Looks good, what towers are those? The total cost without shipping was $200. I regularly carry large loads including awning, kayak, camping gear, jerry cans of fuel and water, spare wheels and all sorts of stuff. 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. DIY Extruded Aluminum Roof Rack. This rack would otherwise hold a lot more, so use your best judgement and research your vehicle. This isn't 100% accurate, since it is possible for me to have a handmade bracket not precisely line up with the laser marked guide, but it's close enough. I didn't know this source was out there, and it's a one-day UPS Ground distance from me :). 4. You must log in or register to reply here. 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. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Almost 3 weeks before I received the order. The side-view shot shows the 80/20 10 series 1x2 extruded rail attached, before I cut it to length. Saved by Carol-Ann Mulkey. One bolt is strong enough, but two provides a little redundancy, always a good idea. One of the things I love most about the Extruded Aluminum (8020) material is how strong it is. 4th and 5th revisions were for functional testing. They also sell lots of connectors and accessories, kind of like an industrial erector set. The bolt holes aren't all in a strait line, but rather follow the contour of the roof. A huge factor to its strength is in the way that it’s fastened to the van. I didn't realize that 80/20 weighs that much. For a better experience, please enable JavaScript in your browser before proceeding. Are you planning to rooftop camp with this? 1 year ago. 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). There are cheaper materials than ext aluminum. I have this saved and voted up in the metalworking contest! It's a simple and cheap way to make a solid roof rack. Next I cleaned it with denatured alcohol and sprayed Cermark on them. 80/20 makes extrusions that easily bolt together using a T-slot design. Im a little late posting the thread, but now after several uses, i can attest to it being solid. For industrial framing or something in a shop, no biggie. This was my 3rd project using 80/20 supplies, and I'm really starting to like working with it! For those who aren't familiar with 80/20 extrusions, I'll give a very brief overview. This is again where you will make decisions based on your use intentions. It's got a complete parts list. If this is going on the roof of you new car, you'll want it blemish free. Toddler Bed. I needed a new rack to support the weight of the roof tent I'm building, so it was time for a stronger rack. And, the aluminum will save weight as well. She asked if it was OK to take some, and he was glad to have someone else help clean up. Discover the magic of the internet at Imgur, a community powered entertainment destination. **Roof racks and roof rack accessories may interfere with factory roof mounted satellite antennas. 3. Here is a roof rack i build from a ladder and some roof rails i didn't use. 95. 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. I don't plan to leave the wide bars on regularly. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. . 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. Also, I knew I wanted to make these out of aluminum, so in versions 4&5 I modified the bracket with the angled fronts so I could condense the set of 4 pieces onto a single 6" x12" plate of 1/4" thick 6061 aluminum. It's all aluminum? If you have another roof type, you will have to come up with your own connection method. Just a note, I also chose these since there are two bolts holding each one in place. More information... People also love these ideas. Also how has wind noise been with the T Slot Bars? But if I want to carry large sheets of plywood, I'll want to use these extra wide cross bars. I made this fit very tight so I had to compress the foam to get all the bolts to line up. I'm very glad you posted this. Each pair of holes was measured, and they all turned out to be the same distance apart, 120mm between holes. all in... Yep, big bits are aluminum. I could potentially make something for you, but can you sketch it on paper and post the image here so I better understand? 89. DIY Extruded Aluminum Roof Rack. 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. 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. It looks uber light weight. FREE Shipping. DIY Extruded Aluminum Roof Rack. That extruded aluminum was something I wanted to try, as I see it often in restroom stall wall applications. Before making these out of aluminum, I used 1/4" Baltic Birch. And in my experience Autobahn Cops will spot this a mile away and pull you right over especially in Germany. i might be significantly cheaper both in cash and in labor. Article by Palma Emmerich. Looks like it's pretty useful and sturdy. Jul 2, 2016 - An 80/20 extruded aluminum commercially produced roof rack. If you've been in the market for an automotive roof rack, you've probably noticed there are already a lot of options. Real weight: if I ever take it off, I'll try to get a weight. 7211 views on Imgur: The magic of the Internet. If you had a local vender that sold 80/20, you could pick it up and save that shipping. With access to a laser cutter, this made precision testing easy, and much cheaper and quicker than making it from aluminum to only realize I needed to refine the fit. In the end, to feel more comfortable than "eyeballing" the angle, I set a laser pointer on the extruded rail, and used a piece of metal shelf support to see where the laser intersected it from a close distance, then move about 20 feet back and measured again. Is the 80/20 stuff that heavy? DIY Extruded Aluminum Roof Rack - diy post. 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 used PLAyPHAb filament which seems to be holding up to the UVs good so far. Oh, I didn't know McMaster sold 80/20! 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. This is still a prototype piece I'm planning to refine later, but it does a good job as is. MaxxHaul 46" x 36" x 4-1/2" - 150 lb. 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. 80/20 also offers so many options, it makes it really easy to make a rack all your own. 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. I ended up using UniStrut. 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. I found in the past that 80/20 extrusions bought on Amazon often come poorly wrapped and get scuffed. Question * carry Yakima skybox and ski rack at the same time. while i like the instructable and the application, i would suggest that you visit the nearest wrecking yard to see if they have roof racks specific to your car. This helped me eyeball if the angle/tilt front to back was good. Explore. 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. FREE Shipping. 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. I’ve been doing an entire day’s worth of (research) regarding the application of extruded aluminum for a rack on my Jeep.I’m wondering if that 3D printed endcap profile could be modified to work in 90* with a smooth outside radius. Not everyone just wants “Plug & Play”. I suspect this is a lighter than steel would be for the same size though i suspect welds are lighter than the hardware. Since this comes from multiple 3rd-party rack venders, I'm assuming this is based on the roof limitations. Steel hardware 60+ m8 bolts, washers, and slotted nuts add up a bit. 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. The idea of me learning the whole CAD design (thing) is a non-starter. I’m in California, FWIW.Regards,StanDogRescuer@iCloud.com, Answer Why take the time to build one yourself? The bolt is a sub-compact car. Well it looks killer and it goes without saying that it is HIGHLY modular and with a roof rack that is key. If there was a significant angle up or down, it would be amplified in the measurement over this distance. Only 5 left in stock - order soon. . I should have covered that! It is expensive stuff for a reason. 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. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. I would have guessed 35 pounds on that thing, but I have never handled the 80/20 extrusions. We have an older Thule rack on there and on lot of occasions I've been up there on the roof securing bulky items.Regarding wind noise, with those pictured 64" cross bars, you do hear it on the highway if the radio is off. They are nor as durable as metallic or aluminum roof racks. How To Fasten Extruded Aluminum (8020) To Your Van. I did this roof rack mod over the summer. 80/20 T-slot extruded aluminum (aka - the industrial erector set) is very lightweight and in my opinion very strong. I had 3 general uses in mind: * be able to carry home 4x8 plywood and other bulky lumber with out hauling a trailer. 80/20 does an impeccable job wrapping and shipping the parts, really very excellent. 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 recommend to anyone to go the direction that gives them the most satisfaction. Most car roof racks are proprietary, and yeah, you can probably buy a factory rack to work, but where's the fun in that? Also you can think about adding a 3rd or even 4th cross bar if that makes sense for your applications. To finish up the install I added flat covers to the ends of the cross bars, and a rubber tread strip along each cross bar. Once my outline shapes were very close, I sanded it by hand with wet/dry paper at 220, 320, 400, and 600 grit. The profile I chose was a 1"x2" from the "10 series" line. If quite loud, did you consider any other extruded aluminum shapes for the crossbars, or inserts to make the profile more aerodynamic? If you have a Chevy Bolt, you are in luck. Aluminum, extra-wide, basket-style cargo carrier is … It comes next day and it's well packaged with reasonable shipping. DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. Reply Did you make this project? Finally, I used some 3D printing filament, a couple dollars worth. The plan is for three cross beams to mount my Yakima Mega Basket. Extruded Aluminum. This is a roof rack that is ALMOST all DIY. It's not readily findable in a google search though. My plan is to not always leave these extra long bars on there though. https://www.thingiverse.com/thing:3075719. @ylexlot Material Choice Question, looking to do a similar, albeit more simplified rack. Even though this worked, it took up my whole back seat/cargo area, and I had to slide my seat all the way forward. Made this in my dads home shop. - 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! I modeled the end cap in Fusion360, based off the diagram 80/20 provides. How's the wind noise? Alibaba offers 577 Aluminium Roof Rack Extrusions Suppliers, and Aluminium Roof Rack Extrusions Manufacturers, Distributors, Factories, Companies. My wife's mini van would be a better contender for rooftop camping. On my Chevy Bolt, all the literature I can find about roof racks mentions a 160lb max capacity. Some people, like myself, take pride in the (journey) of creating, and making something from ‘scratch’. They do add a little wind noise, and wind resistance. These can be installed easily, quickly, and are durable products. This was the hardest step for me. Thanks for providing the detail plans and very specific applications to your car! The rack has been great so far, and I don't really have any thoughts for changes if I were to do it again. I like getting 80/20 from McMaster. Thanks! $129.89 $ 129. $306.95 $ 306. MaxxTow 27x47 Cargo Carrier w/ Pivoting Ramp - 2" Hitches - Extruded Aluminum - 500 lbs MaxxTow Hitc. My sub-compact Chevy Bolt was not the ideal vehicle for getting plywood from my local lumber yard. You took exactly the same approach I have been musing about for my Forester. The wood gets sawdust in the car, and will scuff the plastic trim if I'm not careful. expeditionportal A roof rack made out of aluminum is guaranteed to last you a long time! DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. DIY Aluminium Roof Rack Aluminum is an excellent material to use for your DIY roof rack, as it is a very strong metal and has the capacity to carry a lot of weight over long distances. I'd remove the cross bars if I'm not planning to use them. Share it with us! But in my case it was about 2 weeks between when I order online and when they shipped it UPS ground. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Add a few lb for hardware and the mounts. JavaScript is disabled. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register. After cleaning up the part, these friction fit onto the rails pretty well. No need to find smooth ground for a tent. I didn't go far with it, or I would have lashed a bit more. . 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. Please call a customer service representative for more details. Rola 59043 Atlas Aluminum Rooftop Cargo Basket. Maybe a little spendy for DIY, but not bad considering it is 1 banana project requiring no fab skills. Shipping from 80/20 for me was about $33.00, but I did include some other items not used in this project. Nov 3, 2019 - This Pin was discovered by Jared Sutmiller. Nov 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. The process you describe to build up the angles is great! 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 bought some 80/20 from Amazon and a second shipment right from 80/20. Furniture Home Decor Child Bed Homemade Home Decor Home Furnishings Interior Design. I even opted for the "lite" cross sections that have less aluminum. Shipping for me was about $33. 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. There are 83 OEM, 76 ODM, 67 Self Patent. 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. - Since you know how you plan to use the roof rack, you can make it infinitely adjustable to your needs.

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