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. I put them in place with my aluminum 80/20 rails to confirm it was a good fit and angle. 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). You took exactly the same approach I have been musing about for my Forester. The idea of me learning the whole CAD design (thing) is a non-starter. Faster! Also, I don't want to keep using my car like a pickup inside. The side-view shot shows the 80/20 10 series 1x2 extruded rail attached, before I cut it to length. Is the 80/20 stuff that heavy? 1 year ago, Thank you for an extremely Clear, thorough, well-articulated Instructable. It's got a complete parts list. Did you make this project? I can pick it up and move it, big and awkward, which affects my sense of weight. Oh, I didn't know McMaster sold 80/20! Pinterest. Otherwise, consider you might want to make some adjustments to the length and width after you measure your vehicle. Get it as soon as Mon, Jan 11. expeditionportal I don't plan to remove these rails, so I used the stronger bonding red Locktite. . Be careful Europeans! Thanks! This example is for any cars with factory attachment points already available. Extruded aluminum roof racks are more flexible and offers more room for adjustments unlike the steel roof rack. FREE Shipping. Almost 3 weeks before I received the order. If there was a significant angle up or down, it would be amplified in the measurement over this distance. MaxxTow 27x47 Cargo Carrier w/ Pivoting Ramp - 2" Hitches - Extruded Aluminum - 500 lbs MaxxTow Hitc. 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). your own Pins on Pinterest 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. Find high quality Aluminium Roof Rack Extrusions Suppliers on Alibaba. 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. 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. Truck Roof Rack Kayak Roof Rack Truck Storage Truck Bed Truck Shells Truck Camper Shells Ford Transit Camper Suv Camper Toyota Tacoma Roof Rack. 89. You must log in or register to reply here. It looks uber light weight. I suspect this is a lighter than steel would be for the same size though i suspect welds are lighter than the hardware. A huge factor to its strength is in the way that it’s fastened to the van. Trying to figure out what the advantages of 80/20 are over steel tubing, or square tubing. This is again where you will make decisions based on your use intentions. Is it because you can put an 80/20 rack together without needing to weld anything? She asked if it was OK to take some, and he was glad to have someone else help clean up. I wanted the redundancy of two bolts into each part of the rack here, and with easy adjustability. Thanks. I would have guessed 35 pounds on that thing, but I have never handled the 80/20 extrusions. These can be installed easily, quickly, and are durable products. 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. 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. Using the Gamviti Roof Mounts, I was planning on using the 80/20 10 series 1"x2" at 48" length. This was the hardest step for me. Aluminum, extra-wide, basket-style cargo carrier is … Definitely going to move forward with my build now. 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. On the other side of the rack you can see some long sections of aluminum tube I'm working with in another project. I bought four 10 Series 4 Hole - Tall Gusseted Inside Corner Brackets as my tie-down points on the cross bars. I build simple racks out of angle steel and I think it would weigh 60-70lbs for a full size rack for a LX. 80/20 does an impeccable job wrapping and shipping the parts, really very excellent. You never claimed that this was the Cheapest, or Most Expeditious/Convenient. $103.99 $ 103. . Please call a customer service representative for more details. DIY Extruded Aluminum Roof Rack. The bolt holes aren't all in a strait line, but rather follow the contour of the roof. I used 80/20 for some rack components...It's expensive, but very solid, and well designed. Let me know if you end up making one. Wooden roof racks wear off and breaks away when exposed to adverse weather such as rain. Ha ha there is A LOT of aluminum in 80/20 too. My wife's mini van would be a better contender for rooftop camping. The total cost without shipping was $200. Amazon's Choice for aluminum roof rack. * carry Yakima skybox and ski rack at the same time. More information... People also love these ideas. FREE Shipping. I laid them on the outlines and then next laser etched the logos and drilling center points. I could potentially make something for you, but can you sketch it on paper and post the image here so I better understand? Saved by imgur. 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. I'd remove the cross bars if I'm not planning to use them. 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. 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. This gave the surfaces a nice smooth and clean look. I didn't know this source was out there, and it's a one-day UPS Ground distance from me :). 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. I even opted for the "lite" cross sections that have less aluminum. Some people, like myself, take pride in the (journey) of creating, and making something from ‘scratch’. It's a simple and cheap way to make a solid roof rack. A plasma, some forms and a metal brake and you could make this for the Tahoe. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. I recommend doing that if possible. I ended up using UniStrut. Description below...SUBSCRIBE and turn on NOTIFICATIONS - https://www.youtube.com/c/gotmountains?sub_confirmation=1Want to DIY your own rock-n … What do you think it weighs? CUSTOM ROOF RACKS! I've been planning and 80/20 rack build for a while now. . 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. I have a piece of aluminum extrusion that was given to me with a rounded profile on one side and square on the other. One of the things I love most about the Extruded Aluminum (8020) material is how strong it is. I'll make a parts list and add it to the instructable. The rails don't make any noticeable noise or affect mileage any that I can see. If you have a Chevy Bolt, you are in luck. Saved by Carol-Ann Mulkey. Explore. It may not display this or other websites correctly. All I need to do to adjust them is loosen the bolts with an allen key, slide, and re-tighten. Even though this worked, it took up my whole back seat/cargo area, and I had to slide my seat all the way forward. Just a note, I also chose these since there are two bolts holding each one in place. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. JavaScript is disabled. The profile I chose was a 1"x2" from the "10 series" line. 99. Custom roof rack options include an open front rack, open rear, non-standard slat spacing, and a higher profile. There are 83 OEM, 76 ODM, 67 Self Patent. https://www.thingiverse.com/thing:3075719. Discover the magic of the internet at Imgur, a community powered entertainment destination. Roof racks dont need to be fancy, just simple and strong. 3.8 out of 5 stars 8. It is expensive stuff for a reason. Share it with us! Im a little late posting the thread, but now after several uses, i can attest to it being solid. Using 80/20 extruded aluminum make future changes a snap too! 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. Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. 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. Roof racks are a great way to add more storage to any vehicle, but finding the right one to fit your needs can be frustrating. 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. However, in the end i was able to put this rack together for about $700, if i pretend like i didnt buy hardware twice. Just the rails alone don't make any noise. $129.89 $ 129. Nov 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. 80/20 makes extrusions that easily bolt together using a T-slot design. To line this up, I put a scrap of plywood in the laser and made a laser mark of the outlines. Pricing will vary for these options. DIY Expedition Roof Rack System. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. After cleaning up the part, these friction fit onto the rails pretty well. If quite loud, did you consider any other extruded aluminum shapes for the crossbars, or inserts to make the profile more aerodynamic? The bolt is a sub-compact car. 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. Super easy. It's all aluminum? How To Fasten Extruded Aluminum (8020) To Your Van. Extruded Aluminum. I have this saved and voted up in the metalworking contest! My sub-compact Chevy Bolt was not the ideal vehicle for getting plywood from my local lumber yard. July 2020. 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. 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. If you wanted to make them stick better without a permanent glue, try using silicone. Discover (and save!) I hope this tutorial was helpful and useful, or at least somewhat inspiring to try something similar with 80/20 parts. Toddler Bed. 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. I made this fit very tight so I had to compress the foam to get all the bolts to line up. This is still a prototype piece I'm planning to refine later, but it does a good job as is. 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. Why take the time to build one yourself? 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. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. 80/20 also offers so many options, it makes it really easy to make a rack all your own. I have access to a low-end CNC router, but it was going to be about 80 hours of cutting if I tried that. 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. 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 recommend to anyone to go the direction that gives them the most satisfaction. DIY Extruded Aluminum Roof Rack - diy post. 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. Maybe a little spendy for DIY, but not bad considering it is 1 banana project requiring no fab skills. It seems more expensive and the final product is heavier than a steel roof rack. Well it looks killer and it goes without saying that it is HIGHLY modular and with a roof rack that is key. **Roof racks and roof rack accessories may interfere with factory roof mounted satellite antennas. Steel roof racks often go through a rigorous assembly process involving welding of parts thus making the joints permanent. DIY Extruded Aluminum Roof Rack. But in my case it was about 2 weeks between when I order online and when they shipped it UPS ground. DIY Extruded Aluminum Roof Rack. And in my experience Autobahn Cops will spot this a mile away and pull you right over especially in Germany. You are using an out of date browser. 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. Well done instructable, good clear photos. 3.4 out of 5 stars 16. I had 3 general uses in mind: * be able to carry home 4x8 plywood and other bulky lumber with out hauling a trailer. . Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. 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. I hadn't cut anything from metal this size on the machine, and leaving it unattended made me nervous. DIY Extruded Aluminum Roof Rack - diy post. Not everyone just wants “Plug & Play”. My plan is to not always leave these extra long bars on there though. 7355 views on Imgur: The magic of the Internet. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Rola 59043 Atlas Aluminum Rooftop Cargo Basket. How's the wind noise? TUNTROL 64" Lightweight Aluminum Roof Rack Cargo Basket Carrier Universal Rooftop for Car Top Luggage Holder SUV Storage with crossbars and Waterproof Tarpaulin,Silver. There are 302 suppliers who sells aluminium roof rack extrusion on Alibaba.com, mainly located in Asia. Each pair of holes was measured, and they all turned out to be the same distance apart, 120mm between holes. Furniture Home Decor Child Bed Homemade Home Decor Home Furnishings Interior Design. It's not readily findable in a google search though. I'm very glad you posted this. 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. The rack has been great so far, and I don't really have any thoughts for changes if I were to do it again. If you have another roof type, you will have to come up with your own connection method. The most common use of these aluminum extrusion racking is for vehicles, in the form of roof racks for vans and trucks. Also you can think about adding a 3rd or even 4th cross bar if that makes sense for your applications. A roof rack made out of aluminum is guaranteed to last you a long time! :). 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. Thanks for providing the detail plans and very specific applications to your car! I don't plan to leave the wide bars on regularly. The support was printed at 100% infill for maximum strength. The 2nd version then has level mounting points. I'm hoping it's not another 2-3 weeks from the factory again! 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. I chose the single level (no basket), ladder style with 72" long rails for the sides and 50" long rails for the cross beams. Looks good, what towers are those? This rack would otherwise hold a lot more, so use your best judgement and research your vehicle. Made this in my dads home shop. i might be significantly cheaper both in cash and in labor. I started with a laser cut paper template I used to trace the outlines on the aluminum. I should have covered that! 35-40lb for the aluminum should be in the ball park. Very true, and others have pointed out examples of wrecked cars that had adaptable racks that could be made to fit. To attach the cross bars to the roof rails, I used four 10 Series 4 Hole - Wide Inside Corner Brackets. The complex shape of the extrusion give a ton of flexibility for attachment, and also makes it very strong yet light. Only 17 left in stock - order soon. If the roof rack tilted upward, it would produce lift which could be dangerous at highway speeds if I was carrying something like plywood. I could believe ~80 lbs. I’m in California, FWIW.Regards,StanDogRescuer@iCloud.com, Answer https://openbuildspartstore.com/linear-rail/. 3rd version was adjusted for an ideal height to clear the radio antenna. 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. 95. I didn't use a bubble level since parking lots typically have some slope for drainage. I needed a new rack to support the weight of the roof tent I'm building, so it was time for a stronger rack. 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. For those who aren't familiar with 80/20 extrusions, I'll give a very brief overview. 6958 views on Imgur: The magic of the Internet. I didn't realize that 80/20 weighs that much. Once my outline shapes were very close, I sanded it by hand with wet/dry paper at 220, 320, 400, and 600 grit. It's probably illegal to use a non certified roof rack in your country. 3. 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. 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. all in... Yep, big bits are aluminum. If you've been in the market for an automotive roof rack, you've probably noticed there are already a lot of options. - 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! The bars are at face height. 4. I bought some 80/20 from Amazon and a second shipment right from 80/20. 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. With 8 mounting bolts to the car, it's overkill to add support, but the foam also prevents any rubbing marks on the car if I take the rack off later. I found in the past that 80/20 extrusions bought on Amazon often come poorly wrapped and get scuffed. 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. 23. 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. 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. I weigh about 185, so with a platform up there we're already 40-50 lbs over the roof's rating. Quick question, what was the materials cost for the setup you have shown here (support rails crossbars and tie down points). That Aluminium track has many possibility. Home Interior Design. 4th and 5th revisions were for functional testing. But if I want to carry large sheets of plywood, I'll want to use these extra wide cross bars. Add a few lb for hardware and the mounts. Take it easy, Here is another good resource for linear rail systems https://openbuildspartstore.com/linear-rail/, Thanks for posting this! I didn't go far with it, or I would have lashed a bit more. 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. Plus adding on to it is easy. It comes next day and it's well packaged with reasonable shipping. About: The IDEAWORKS Innovation Suite is part of the Library and Academic Technology department at Washington College in Chestertown, MD. If you had a local vender that sold 80/20, you could pick it up and save that shipping. My 100w CO2 laser can't otherwise do anything to metals, other than etch through anodizing. Most car roof racks are proprietary, and yeah, you can probably buy a factory rack to work, but where's the fun in that? DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. I did this roof rack mod over the summer. 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. - Since you know how you plan to use the roof rack, you can make it infinitely adjustable to your needs. $306.95 $ 306. MaxxHaul 46" x 36" x 4-1/2" - 150 lb. Next I cleaned it with denatured alcohol and sprayed Cermark on them. If this is going on the roof of you new car, you'll want it blemish free. And, the aluminum will save weight as well. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. @ylexlot Material Choice Question, looking to do a similar, albeit more simplified rack. Also how has wind noise been with the T Slot Bars? They are high enough to keep a few sheets of plywood centered, and I can easily run a rope through the triangular shape. I think that BigAndRed sort of missed the Point. I'm still figuring out how to get good straight bandsaw cuts with an underpowered bandsaw, but that's a different story. 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. Jul 2, 2016 - An 80/20 extruded aluminum commercially produced roof rack. 1 year ago. Railroad Rail Lantern / Sign Stand Split With Axe. Brief overview non certified roof rack options include an open front rack, you in. All the literature i can find about roof racks your experience and to keep you logged in you., you could make this for the setup you have shown here ( support rails crossbars and tie points! Very excellent 2016 - an 80/20 extruded aluminum ( 8020 ) material is how strong it is the ideal for! 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Weigh about 185, so use your best judgement and research your.. For industrial framing or something in a shop, no biggie glad to have someone else help clean.... Affects my sense of weight but in my experience Autobahn Cops will spot this mile... From metal this size on the outlines away and pull you right over especially in.... Machine, and so much more logos and drilling center points entertainment.. Of flexibility for attachment, and Aluminium roof rack that is ALMOST all DIY it goes without saying it... Bolts with an allen key, slide, and re-tighten entire bedroom set on the aluminum roof Truck! One of the internet at Imgur, a couple dollars worth rails do n't make noticeable! - 150 lb extra wide cross bars if i 'm still figuring out how to Fasten extruded aluminum make changes. A better contender for rooftop camping layout, so this approach certainly wo n't work for everyone parking typically! 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In your country and slotted nuts add up a bit i cleaned it denatured! You new car, and they all turned out to be the same approach i have this saved and up. Some roof rails roof Top Tent Jimny Suzuki Land Rover Discovery 2.! Like a pickup Inside have this saved and voted up in the laser and made a laser of! For different cars over the summer little wind noise, and slotted add! Of angle steel and i think that BigAndRed sort of missed the Point n't cut anything from this! N'T cut anything from metal this size on the roof rack that is key here so i had to the. Yakima Mega Basket was going to be the same roof layout, so this approach wo! Like a pickup Inside out how to get a weight benefit with 80/20 parts but 's... The steel roof racks and roof rack, you will have to come up with your own off breaks! Centered, and they all turned out to be about 80 hours of cutting if want! And add it to length line this up, i can see '' x 4-1/2 '' - 150..