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Roof rail project

2K views 2 replies 2 participants last post by  nigelh 
#1 ·
I have Rhino rack ‘Sports’ bars, which only have a load capacity of about 70 kilos, and I need to carry about 100 for a big trip through central Australia next year, (Spare Tyre, and 4 jerry cans). So I needed a rack to carry more, I also have a Rolo basket to attach. Below is my solution.

My bars should spread the load, fully, down each side, with four mount points, 2 at front, one center then one at rear, using std points (No modifications to body). Clearance is 60mm, plenty for sun roof vent. No plastic mounts that could crack on a long off-road trip.

Components:-
• 2 X 20mm x 20mm x 900mm square steel tube
• 8 X 20mm x 20mm x 140mm square steel tube
• 2 X 75mm x 25mm x 1200mm rectangular steel tube
• 4 X 75mm x 25mm x 2mm steel plate endcaps
• 12 X 20mm x 20mm black plastic endcaps
• Total cost, cut to size, $30.00

Just got to get my Brother In law to weld up.

The Basket needs to be sandblasted and then, when finished, both powder coated.

I will update as I progress, the 20 mm tube is about 1 mm too wide for the channel, so the channel needs to be pried open a bit to fit, and a slight curve to match the roof line.
 

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#3 ·
One off, sorry, but should be a simple build, something similar, built in Melbourne, including the basket around $2,500.
 
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