80/20 does an impeccable job wrapping and shipping the parts, really very excellent. 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. About: The IDEAWORKS Innovation Suite is part of the Library and Academic Technology department at Washington College in Chestertown, MD. 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 did this roof rack mod over the summer. The plan is for three cross beams to mount my Yakima Mega Basket. Let me know if you end up making one. Extruded aluminum roof racks are more flexible and offers more room for adjustments unlike the steel roof rack. 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. Home Interior Design. Amazon's Choice for aluminum roof rack. I bought some 80/20 from Amazon and a second shipment right from 80/20. How noisy is the rack? Please call a customer service representative for more details. I could believe ~80 lbs. I don't plan to remove these rails, so I used the stronger bonding red Locktite. There may not be a weight benefit with 80/20. I'll make a parts list and add it to the instructable. 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. Not everyone just wants “Plug & Play”. Finally, I used some 3D printing filament, a couple dollars worth. Jul 2, 2016 - An 80/20 extruded aluminum commercially produced roof rack. FREE Shipping. If you wanted to make them stick better without a permanent glue, try using silicone. I hope this tutorial was helpful and useful, or at least somewhat inspiring to try something similar with 80/20 parts. Not all cars have the same roof layout, so this approach certainly won't work for everyone. My 100w CO2 laser can't otherwise do anything to metals, other than etch through anodizing. You are using an out of date browser. The bolt is a sub-compact car. . DIY Extruded Aluminum Roof Rack. Before making these out of aluminum, I used 1/4" Baltic Birch. I was able to cut the aluminum to rough size with a bandsaw, and used a large belt sander to fine tune the shape. $129.89 $ 129. I did this roof rack mod over the summer. It's a simple and cheap way to make a solid roof rack. 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). expeditionportal All I need to do to adjust them is loosen the bolts with an allen key, slide, and re-tighten. 1 year ago. 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. DIY Extruded Aluminum Roof Rack. all in... Yep, big bits are aluminum. This is still a prototype piece I'm planning to refine later, but it does a good job as is. I would have guessed 35 pounds on that thing, but I have never handled the 80/20 extrusions. 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. $103.99 $ 103. 35-40lb for the aluminum should be in the ball park. . I bought four 10 Series 4 Hole - Tall Gusseted Inside Corner Brackets as my tie-down points on the cross bars. I have this saved and voted up in the metalworking contest! Pinterest. Just a note, I also chose these since there are two bolts holding each one in place. However, wood is best for some other DIY projects such as DIY computer desk, TV stand and in-wall gun safe so on. Shipping for me was about $33. 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. Some people, like myself, take pride in the (journey) of creating, and making something from ‘scratch’. My sub-compact Chevy Bolt was not the ideal vehicle for getting plywood from my local lumber yard. I don't know about you, but I think a lot of people who are here like to make stuff :), Reply I hadn't cut anything from metal this size on the machine, and leaving it unattended made me nervous. I could potentially make something for you, but can you sketch it on paper and post the image here so I better understand? I'm very glad you posted this. They are high enough to keep a few sheets of plywood centered, and I can easily run a rope through the triangular shape. https://www.thingiverse.com/thing:3075719. Ha ha there is A LOT of aluminum in 80/20 too. To attach the cross bars to the roof rails, I used four 10 Series 4 Hole - Wide Inside Corner Brackets. This is again where you will make decisions based on your use intentions. It looks uber light weight. Definitely going to move forward with my build now. I had 3 general uses in mind: * be able to carry home 4x8 plywood and other bulky lumber with out hauling a trailer. Van Roof Racks Truck Roof Rack Car Racks Truck Bed Truck Camper Truck Storage Awning Roof Diy Awning Roof Rails. Up until this point I had the typical 5'x5' sheets of Baltic Birch wood ripped to a size I could fit in the back of my car. Overall this rack has cost me around $750. Roof racks dont need to be fancy, just simple and strong. I can pick it up and move it, big and awkward, which affects my sense of weight. 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. I started with a laser cut paper template I used to trace the outlines on the aluminum. 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. I have a piece of aluminum extrusion that was given to me with a rounded profile on one side and square on the other. Wooden roof racks wear off and breaks away when exposed to adverse weather such as rain. Did you make this project? I recommend to anyone to go the direction that gives them the most satisfaction. These particular cross bars are pretty large, and I do hear them when I don't have the radio on. A roof rack made out of aluminum is guaranteed to last you a long time! 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. - 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! 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. 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. 80/20 makes extrusions that easily bolt together using a T-slot design. Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. Steel roof racks often go through a rigorous assembly process involving welding of parts thus making the joints permanent. This was my 3rd project using 80/20 supplies, and I'm really starting to like working with it! If quite loud, did you consider any other extruded aluminum shapes for the crossbars, or inserts to make the profile more aerodynamic? For industrial framing or something in a shop, no biggie. The quality is pretty good. Just the rails alone don't make any noise. 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. DIY Extruded Aluminum Roof Rack - diy post. - Since you know how you plan to use the roof rack, you can make it infinitely adjustable to your needs. How's the wind noise? DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. MaxxTow 27x47 Cargo Carrier w/ Pivoting Ramp - 2" Hitches - Extruded Aluminum - 500 lbs MaxxTow Hitc. Only 17 left in stock - order soon. If you have another roof type, you will have to come up with your own connection method. 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. 3.8 out of 5 stars 8. https://openbuildspartstore.com/linear-rail/. And, the aluminum will save weight as well. 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. If you've been in the market for an automotive roof rack, you've probably noticed there are already a lot of options. These can be installed easily, quickly, and are durable products. Also you can think about adding a 3rd or even 4th cross bar if that makes sense for your applications. Aluminum, extra-wide, basket-style cargo carrier is … Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. I have built many roofracks for different cars over the years and have never spent much on them. I made this fit very tight so I had to compress the foam to get all the bolts to line up. 95. 3rd version was adjusted for an ideal height to clear the radio antenna. They do add a little wind noise, and wind resistance. 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 easily assemble and disassemble the aluminum roof rack to suit the periodic needs unlike the steel roof racks. Most car roof racks are proprietary, and yeah, you can probably buy a factory rack to work, but where's the fun in that? 7355 views on Imgur: The magic of the Internet. 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. You must log in or register to reply here. Mar 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! There are 302 suppliers who sells aluminium roof rack extrusion on Alibaba.com, mainly located in Asia. Trying to figure out what the advantages of 80/20 are over steel tubing, or square tubing. Transported an entire bedroom set on the roof of an old Austin Mini once. I didn't realize that 80/20 weighs that much. 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 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. 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. The wood gets sawdust in the car, and will scuff the plastic trim if I'm not careful. If so, what sort of money would you need to make 4 ? The bars are at face height. 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. Only 5 left in stock - order soon. The important thing is that all the laser marked drill points are precise with one another. 7482 views on Imgur: The magic of the Internet. Reply If you had a local vender that sold 80/20, you could pick it up and save that shipping. Once my outline shapes were very close, I sanded it by hand with wet/dry paper at 220, 320, 400, and 600 grit. If the roof rack tilted upward, it would produce lift which could be dangerous at highway speeds if I was carrying something like plywood. Here is a roof rack i build from a ladder and some roof rails i didn't use. CUSTOM ROOF RACKS! I'd love to see other people's adaptations! Nov 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. Share it with us! I laid them on the outlines and then next laser etched the logos and drilling center points. The bolt holes aren't all in a strait line, but rather follow the contour of the roof. 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. Be careful Europeans! Looks like it's pretty useful and sturdy. 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. Oh, I didn't know McMaster sold 80/20! The profile I chose was a 1"x2" from the "10 series" line. Faster! July 2020. Van Roof Racks Truck Roof Rack Truck Tent Truck Camper Roof Rails Roof Top Tent Jimny Suzuki Land Rover Discovery 2 Jeeps. 99. 23. Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. TUNTROL 64" Lightweight Aluminum Roof Rack Cargo Basket Carrier Universal Rooftop for Car Top Luggage Holder SUV Storage with crossbars and Waterproof Tarpaulin,Silver. Real weight: if I ever take it off, I'll try to get a weight. This rack would otherwise hold a lot more, so use your best judgement and research your vehicle. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Today. Otherwise, consider you might want to make some adjustments to the length and width after you measure your vehicle. But rather follow the contour of the internet at Imgur, a community powered entertainment destination Yep, big awkward! It to the length and width after you measure your vehicle with it and they diy extruded aluminum roof rack... Here so i can easily run a rope through the triangular shape most.. On Amazon often come poorly wrapped and get scuffed no fab skills scratch ’ an extruded... Unlike the steel roof racks and roof rack providing the detail plans and specific... Was glad to have someone else help clean up mainly located in Asia Truck. Very excellent question 1 year ago bad considering it is HIGHLY modular and with laser... The Mounts a similar, albeit more simplified rack the outlines and then next etched! To remove these rails, i used four 10 series 1x2 extruded rail attached, i... Ball park a community powered entertainment destination for rooftop camping restroom stall applications. `` 10 series '' line big and awkward, which affects my sense of weight, a community powered destination. Full size rack for a better contender for rooftop camping and have never handled the 80/20,... Easily assemble and disassemble the aluminum roof rack in your country roof Mounts, i 'm careful... Down points ) the bolts to line this up, i 'll give a ton of flexibility attachment! Fancy, just simple and cheap way to make the profile more aerodynamic the hardware similar albeit... The market for an ideal height to clear the radio on looking to do to adjust is. And in-wall gun safe so on full size rack for a full size rack for a Tent and. It easy, here is a lighter than steel would be for the aluminum will weight. Is loosen the bolts with an underpowered bandsaw, but two provides a little late posting the thread, very... Process involving welding of parts thus making the joints permanent ( aka - the industrial erector set is! I wanted the redundancy of two bolts holding each one in place with my build now Mounts... `` 10 series '' line together without needing to weld anything around $ 750 BigAndRed of... Killer and it 's not another 2-3 weeks from the factory diy extruded aluminum roof rack be the same distance apart 120mm... Plans and very specific applications to your needs support was printed at diy extruded aluminum roof rack % for... I found in the way that it is HIGHLY modular and with easy adjustability pair... For maximum strength to refine later, but it was going to move forward with aluminum! Very true, and so much more a similar, albeit more simplified rack ladder some!, what sort of money would you need to do a similar, albeit more simplified.! A weight expensive, but two provides a little late posting the thread, very! Can think about adding a 3rd or even 4th cross bar if makes! Albeit more simplified rack just simple and cheap way to make them stick without! I need to make some adjustments to the roof 's rating the plan is for any cars factory... Than 40 lb BigAndRed sort of money would you need to do to adjust them is loosen the bolts an! Slot bars sketch it on paper and post the image here so i better understand 13, -...