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View Full Version : Homemade Roof Rack without Welding



4x4Dalton
05-21-2011, 08:14 PM
https://lh4.googleusercontent.com/_BalGd56uEqU/TdhfTM-L0hI/AAAAAAAAAuA/MkiBXGsRDWU/s640/260.JPG

Ok I know yall have been waiting for this post. Here is the Roof Rack I made without welding. Enjoy the pics. First is what ya need to make it.
https://lh5.googleusercontent.com/_BalGd56uEqU/Tdha41L10LI/AAAAAAAAAqA/qZD53g-nbpo/s640/236.JPG perfect size for the 3/4 emt conduit.
https://lh5.googleusercontent.com/_BalGd56uEqU/TdhbKs_y39I/AAAAAAAAAqQ/A0NL_c5lWoI/s640/237.JPG 4 inch plates for the sides and front and back support.
https://lh5.googleusercontent.com/_BalGd56uEqU/TdhbTBvQB8I/AAAAAAAAAqU/3XfX2oNUcqc/s640/238.JPG Got this at Lowes..5ft pieces ya need 6 of them.
https://lh3.googleusercontent.com/_BalGd56uEqU/TdhbnW5xSLI/AAAAAAAAAqo/oTBaK-sshZE/s640/239.JPG 90 degree elbows(cause I didnt have a bender)
https://lh4.googleusercontent.com/_BalGd56uEqU/TdhcfJ2f-TI/AAAAAAAAArM/A_B5I3rXblA/s640/240.JPG One of the sides measures 52 inchs
https://lh6.googleusercontent.com/_BalGd56uEqU/TdhcsVfwigI/AAAAAAAAArg/V2MITjDo2Mc/s640/241.JPG Also found that one of these comes in handy.
https://lh3.googleusercontent.com/_BalGd56uEqU/TdhdlisEfPI/AAAAAAAAAsE/kaeVU1ayRrA/s640/244.JPG One end already done and lay elbow out to 52 inchs mark and cut conduit.
https://lh5.googleusercontent.com/_BalGd56uEqU/Tdhdvs5K_nI/AAAAAAAAAsc/Bjj2Wnx3SQQ/s640/245.JPG Takin a break and wonderin about the end of the world :D .
https://lh6.googleusercontent.com/_BalGd56uEqU/TdheIClxtdI/AAAAAAAAAs0/II7ltX7uh9o/s640/247.JPG Always can use a helper.
https://lh4.googleusercontent.com/_BalGd56uEqU/TdheP4KYkyI/AAAAAAAAAs4/dQREDna51VM/s640/248.JPG One section finished.
https://lh4.googleusercontent.com/_BalGd56uEqU/TdhexxgschI/AAAAAAAAAtk/O8dIFIVt4Uw/s640/251.JPG Almost there.
https://lh6.googleusercontent.com/_BalGd56uEqU/TdhfK4_y0hI/AAAAAAAAAts/dBlPJxN8sSI/s640/258.JPG Primed and ready for paint.
https://lh4.googleusercontent.com/_BalGd56uEqU/TdhfTM-L0hI/AAAAAAAAAuA/MkiBXGsRDWU/s640/260.JPG Flat Black does a good job on this.
https://lh3.googleusercontent.com/_BalGd56uEqU/TdhfbpEEb1I/AAAAAAAAAuE/bhhcDUSBnjU/s640/262.JPG TAH DAH!!!!!
Now a lil bit about it...
For this project it will take ya about 3-4 hours dependin on how fast ya go. Measure the pieces for the front and back at 27 1/16th. When putting on the brace pieces make sure to line them up across from each other so not to make it look off center. Once it is dried pick it up and be careful not to flip the thing over yer head and hit yerself in the back(Yep I did). Thing is light but strong as hell. Hope this helps anyone wantin to make one this way. Any questions just ask.
BEAR

801 xj ohh rah
05-22-2011, 01:00 AM
that doesnt look too bad think i might try it. so what was the ball park cost on the parts ? if you can remember = )

4.3LXJ
05-22-2011, 11:19 AM
Looks good. It will do the job.

4x4Dalton
05-22-2011, 12:10 PM
Oh yeah went outside grabbed hold of rack gave it a tug and whole XJ moved so it aint budgin. Forgot to add the cost of it all. Cost just shy of $100 for everything.

Punisher
05-22-2011, 12:52 PM
Now thats thinking with your dip-stick....:D
Looks great Bear!

rugidone
05-22-2011, 03:50 PM
Great job! How much you got into the rack?

jccatt
05-22-2011, 04:32 PM
Good job. Now ya gota go wheeling to test it.

bluedragon436
05-22-2011, 09:35 PM
nice design... might take this and change it up a bit when I make mine... great writeup!!

ironmanandy
05-22-2011, 10:43 PM
This is great dude!!!!

Screw the 400.oo POS con fer fall apart rack. That thing is galvanized, primed, painted. Good show my friend. That is genius. and for 100.00 you cant beat it. Well you could and with wouldn't hurt it.
-Andy

steph74
05-23-2011, 09:18 AM
Yeah Bear that it cool.... I just needed a guinea Pig to do it and see how it goes... now I can do it too lol
Thanks for the write-up ;)

RTPG
05-25-2011, 12:42 AM
Dang! Good job and great write up! :thumbsup:

xj4life2
05-25-2011, 12:19 PM
Nice work my friend, I knew ya had it in ya !!! Looks sweet !!

Switch_knuckles
05-25-2011, 11:39 PM
Me likey. Nice write up bear!!!

CT99XJ
05-26-2011, 09:03 PM
This is freakin' cool, man. Bravo!

4x4Dalton
05-27-2011, 04:33 PM
Ok yall I did make a lil mod to the rack. I added 2 more bars in between the 2 on bottom from front to back. Now it will be easier to use the ratchet straps to hold tire down. I'll post a pic of the work as soon as I can.

modestmar00xj
05-30-2011, 01:39 AM
This is seriously amazing! good work! and it looks great too! i think im going to make one now!

modestmar00xj
05-30-2011, 01:45 AM
here's also a good way to mount this rack to the rain gutter.....http://nates4x4.com/catalog/product_info.php?cPath=25&products_id=91

bluedragon436
05-30-2011, 10:35 AM
Looking forward to seeing pics of the additions to the rack.... I was thinking as I was designing out my rack for when I get back home, that I was going to add the additional two bars...

Jdub76
05-30-2011, 03:10 PM
Very nice for the money & time it took!

red82
06-03-2011, 03:49 PM
super nice! How did you mount it to your stock rack? U bolts? Could you get a photo of how you did it? For some reason I'm having a little difficulty seeing how the u bolt would work exactly.

Great job1

4x4Dalton
06-04-2011, 04:02 PM
It is mounted to rails with 2 3/4in.hose brackets and plus I sheet metal screwed the pipe goin front to back on bottom to rails as well. Its tough trust me. I have a hi-lift jack and a 31 up there and you can not move the rack without movin Jeep...lol.

4x4Dalton
06-04-2011, 07:09 PM
Here are a few pics of how it is mounted.
https://lh3.googleusercontent.com/-1nb3AzMX-bM/TerHD5atApI/AAAAAAAAAvk/AWoRTaCi0Do/0604111955.jpg
Mounted it to rails using 4 of these 2&3/4in hose clamps.
Plus bolted the pipe from front to back on bottom to rails with sheet metal screws.
https://lh4.googleusercontent.com/-NOVqjy_bn5I/TerG9hXvnaI/AAAAAAAAAvg/R4Bas_bRHpg/0604111955a.jpg
And heres a pic of how it has been for almost 2 weeks and still no give in it.
https://lh5.googleusercontent.com/-7E1R1Nwo3nE/TerG0R0Vg8I/AAAAAAAAAvc/6iNJlTUvm_U/0604111957.jpg

red82
06-05-2011, 01:11 AM
Thanks so much I've got my next project now that I've seen that.

red82
06-05-2011, 01:21 AM
Oh and what the heck is that clamp looking thing and what did you use it for? :) sorry for all the questions!

4x4Dalton
06-05-2011, 09:23 AM
Oh and what the heck is that clamp looking thing and what did you use it for? :) sorry for all the questions!

Where are ya talkin about? The first pic? If so that is the hose clamp it is wrapped around the pipe and the rail both then tighten down tight. Dont worry bout askin questions bro. Thats what we are all here for,to help,learn and love our XJ's.

red82
06-05-2011, 04:12 PM
In your original post the seventh pic down. A little silver clamp or something you said was useful.

4x4Dalton
06-05-2011, 06:34 PM
Oh..lol. Thats a pipe cutter. Comes in handy when needin to cut the pipe down to correct size.

ironmanandy
06-06-2011, 12:15 AM
A pipe cutter should be on the XJ owners first tools to buy list. They are great for everything from cutting brake lines, pipe cutting (makes a perfect square cut) scribing rounds, cutting caps off beer bottles, etc. Everyone should have one for sure.
Andy

red82
06-07-2011, 12:16 PM
Thanks so much guys!

1ATony
06-10-2011, 01:53 PM
That came out awesome. Looks great.:cool:

4x4Dalton
06-10-2011, 02:45 PM
Ya know with all these vendors likin this. Maybe I should patent it before I see it in a Quadratec catalog...:smiley-laughing021::smiley-laughing021:

alex673
07-10-2011, 12:34 AM
Awesome job man! Thinking I might try building one too! Just hope I can get hold of the galvanized conduit and fittings here in Australia at a reasonable price.

Best

Alex

CherokeeNat.92
07-18-2011, 11:38 PM
4x4dalton...i got the conduit all together i got the 4inch plates..i got the exact screws but i drill the holes and the screws don't stay in. What technique did you have to use to get the screws to stay in. Did you use an adhesive of some sort?

4x4Dalton
07-21-2011, 05:28 PM
Nah bro just elbow grease and some luck lol. Mine all went in good. Are you puttin the plates on inside or outside?

CherokeeNat.92
07-22-2011, 12:16 AM
I put my plates on the inside and instead of using the screws you used..i used flat slotted screws with nuts and used them on the plates and the bars on the bottom. Two on top and bottom on the plates and one on each end of the bars. I don't know if that really helps to make it much stronger than what you went with but it feels pretty solid. Now i just need to mount it. What did you use to put on your Hi Lift? I was thinking U bolts but i wanna see whats being used out there.

bluedragon436
07-22-2011, 01:56 PM
I was going to use a bolt through the side bar, and put a wing nut on the end after I installed the jack.. and find a rubber spacer at hardware store to keep it from rattling all over the rack... then you can get even drill a hole through the bolt to lock your jack up there so no one will rid you of your much needed jack..

4x4Dalton
07-22-2011, 10:04 PM
I put my plates on the inside and instead of using the screws you used..i used flat slotted screws with nuts and used them on the plates and the bars on the bottom. Two on top and bottom on the plates and one on each end of the bars. I don't know if that really helps to make it much stronger than what you went with but it feels pretty solid. Now i just need to mount it. What did you use to put on your Hi Lift? I was thinking U bolts but i wanna see whats being used out there.

I drilled a hole thru the plates on the side and ran a bolt thru them. Then put Hi-Lift on those bolts and used washers and nuts to secure . Think they were 1/2 inch bolts just right fort the holes in Hi-Lift. Hope that helps ya.

Metlic53
07-23-2011, 02:23 PM
i'll be building one of these, i think it looks good, i have 2 racks but have 3 jeeps just need one more! :D

CherokeeNat.92
07-24-2011, 04:16 PM
I drilled a hole thru the plates on the side and ran a bolt thru them. Then put Hi-Lift on those bolts and used washers and nuts to secure . Think they were 1/2 inch bolts just right fort the holes in Hi-Lift. Hope that helps ya.

Not a bad idea. I think i do wanna drill a hole just off the tip of the bolt and see if i can put a lock on it and still take the nut on and off. Granted its not like if someone wants to steal it they can't just cut the lock or something.

wayne sweet
08-14-2011, 02:22 PM
Ok yall I did make a lil mod to the rack. I added 2 more bars in between the 2 on bottom from front to back. Now it will be easier to use the ratchet straps to hold tire down. I'll post a pic of the work as soon as I can.

how did you atttach to roof rack please specify thank you

bluedragon436
08-17-2011, 10:35 AM
If I remember correctly from when I asked him he used U-bolts under the factory cross bars, up and over the lower rack bars..

Jdub76
09-01-2011, 06:12 PM
I gonna do this rack soon. How did you attach the rack to the roof?

CherokeeNat.92
09-02-2011, 12:14 AM
I attached mine with 6 hose clamps. My rack sits on top of 4 rails too. Drove from tacoma,Wa to Philly at speeds up to 75-80 at times and weeks later still no budge. I have my spare tire, hi lift and fuel jug on it.

bluedragon436
09-03-2011, 12:30 PM
Bear used hose clamps to hold is rack up there on the stock cross bars... I was asking him that right after he posted this build up on here!!

Skipper51
09-04-2011, 11:54 PM
This is the easiest and cheapest roof rack I have ever seem. Good job and nice to the point write up.

pmljeep
09-16-2011, 03:56 PM
Great Job. I might take this project on. Thank you for the write up.

Jerman75
09-17-2011, 07:15 AM
SWEET! i was thinking of doing a project like this and now that i see how simple it is im going to do it.

bluedragon436
09-17-2011, 08:15 AM
Make sure you post up pics once you take it on... Like getting to see everyone's take on awesome projects like these!!!

Jerman75
09-26-2011, 05:15 PM
i started my rack yesterday. its a bit larger with different "floor" material. it was so easy i think i might make a few more and sell them. ill post pics when i finish it.

drakan1908
09-29-2011, 09:15 PM
Nice Bear!! If I had known you were gonna do that, I could have come up and brought my conduit bender and bent most of it for you. That way you wouldn't have needed as many couplings.

702XJCruiser
10-05-2011, 12:54 PM
That's awesome. I think it may be my next project.

bluedragon436
10-05-2011, 09:46 PM
Definitely worth the effort to try and build.. I mean I know it won't be the same as a fabrication company made unit.. But will serve my needs just fine.. Can't wait to see pics of everyone's play on this build..

ambitious98xj
10-14-2011, 12:13 AM
Bear, i love your roofrack, thank you so much for sharing! I think you started something, shared it on FB and a few guys in Jeep Group i am in are pricing and planning already!

xjnuttier
11-07-2011, 03:45 PM
Very nice design, I really like that. I have a killer idea for tobe flat fenders for an xj using conduit. I got the bender and welder, so I am kinda fortunate for that :)

budgetxjmcknight
12-13-2011, 05:31 PM
I work with EMT conduit on a daily bases. My concern is it isn't that rigid and if straping something down, its going to bend/ kink. I think a good way to go is with rigid pipe 3/4" and the same kind of connectors but you will have to go with 1" on those but love this Idea and really want to do it for my own. Thanks for a great design.

rikahaem
12-15-2011, 07:16 PM
this is awesome! ive been looking at roof racks for months now and cant justify buying one. this looks like it would work perfectly, plus it'll give me somethin to do over break. i am a bit concerned that the pipe is going to kink or something. but for the price, i almost dont care :)

ColbyAttack
12-22-2011, 03:51 PM
Looks pretty good, I've been trying to find something like this for a while.

mw14c
02-02-2012, 10:01 PM
This rack is the reason I found this site. Never even thought of building one out of conduit. BRILLIANT!!! I built one of my own with a few mods (I welded the seams and changed the measurements a little and added some pulled metal). I would definately put it against the $400 ones advertised and I think it looks better. Some of my friend are wanting me to build them one. Will post pictures if I can. Thanks, you might think of manufacturing these. I really think there is a market as your design is so adjustable.

mw14c
02-03-2012, 07:11 PM
Hey Bear (I guess that's what you go by), I couldn't help but notice from looking at the pictures that one of your crossbar mounts lost its guts. Can I send you one? I've got a couple of extras from the pick-a-part yard and would gladly share one with you for your great write up (it saved me a couple hundred dollars). Give me your mailing address and I'll ship it to you. Thanks, Jim

Mudderoy
02-04-2012, 10:04 AM
Hey Bear (I guess that's what you go by), I couldn't help but notice from looking at the pictures that one of your crossbar mounts lost its guts. Can I send you one? I've got a couple of extras from the pick-a-part yard and would gladly share one with you for your great write up (it saved me a couple hundred dollars). Give me your mailing address and I'll ship it to you. Thanks, Jim

Dalton4x4, "Bear", has been without a computer for several months, so it may be awhile before he responds to you. :thumbsup:

Dragon1900
03-17-2012, 04:45 PM
Hi Bear

Maybe I missed this information in the comments, but what size pipe did you use? I want to do the same project but don't want to go too light a pipe.

Thanks

budgetxjmcknight
03-20-2012, 06:26 PM
From the looks of it, think its 3/4 EMT but could br 1". I had doubts about using EMT but with the kind of bracing Bear used I think it would hold up well, sorry for the doubt, great idea. My problem is what if your factory rails are trying to lift up on you, how to attach?????

RamboneXJ66
03-24-2012, 06:23 PM
thanks for this write up this is awesome, im a jeeper on a budget with little tools or knowledge, lol

HockeyDawg
03-25-2012, 09:27 PM
Great write up. I built one just like this about 6 years ago for my TJ but instead of using brackets to separate the top from the bottom, I used cut lengths of conduit that i fishmouthed with a 1" drill bit on my drill press then used long eye bolts connect it all together. The eye bolts also gave me a good spot to connect bungee cords. I'll see if I can find pictures of it.

bluedragon436
04-03-2012, 10:45 PM
Great write up. I built one just like this about 6 years ago for my TJ but instead of using brackets to separate the top from the bottom, I used cut lengths of conduit that i fishmouthed with a 1" drill bit on my drill press then used long eye bolts connect it all together. The eye bolts also gave me a good spot to connect bungee cords. I'll see if I can find pictures of it.

I look forward to seeing pics of this as I have been thinking of using similar idea for building either a roof rack or a rack in the back of my XJ..

SoCalwheelin
05-18-2012, 07:14 AM
Very cool bear Can u tell me what the over dimensions are

1Akevin
05-23-2012, 08:10 AM
What a great write-up! I'll be showing that to some folks around here. Well done!

drumcon11
06-06-2012, 02:35 PM
I just made one today. It really is surprisingly strong. The most expensive part of this whole project were the 8 elbows. How did you attach the two bottom pipes to the frame? I suppose I could drill through both pipes, but I was wondering if you had a better way.

bluedragon436
06-07-2012, 02:13 PM
Very cool bear Can u tell me what the over dimensions are

You can make it whatever dimensions you want to fit the look you want... You can make it just as wide or wider than your factory rack is, you can make it the full length of the roof, or longer if you want... it is all on what you want...


I just made one today. It really is surprisingly strong. The most expensive part of this whole project were the 8 elbows. How did you attach the two bottom pipes to the frame? I suppose I could drill through both pipes, but I was wondering if you had a better way.

If you are referring to how he did the floor pipes to the frame work... he drilled through the pipes, and used self tapping machine type screws to attach them to the frame work...

jnorine
07-03-2012, 01:35 AM
Looks like a great project, but I couldn't figure out how you attached it to the roof???

4x4Dalton
07-04-2012, 11:44 PM
First thing I did was on the 2 outside pieces that run front to back on bottom was to put a sheet metal screw thru the pipe and cross bar of jeep rack then used a hose clamp at the ends of the jeep rack around the roof rack I made and tighten them down real tight.You can grab the rack pull on it and push and the whole jeep moves so it aint goin anywhere.

ikhan008
09-04-2012, 07:46 AM
very nice i became a new member because of this build!! thank you just got a 95 jeep and need to do work to it, this helps!

Dredwolf
09-28-2012, 10:34 PM
First thing I did was on the 2 outside pieces that run front to back on bottom was to put a sheet metal screw thru the pipe and cross bar of jeep rack then used a hose clamp at the ends of the jeep rack around the roof rack I made and tighten them down real tight.You can grab the rack pull on it and push and the whole jeep moves so it aint goin anywhere.

I will say it as well, awesome design and build. For the price of one prebuilt rack, I could build the rack, add a Hi-lift jack, jack mounts, some lights, and have beer money left over. :D

SeniorGustas
08-13-2013, 01:58 PM
Any one whos done this know how much $$ it cost, its an awesome build and id like to do it this weekend.

Brasscatz
08-14-2013, 07:32 PM
If I remember correctly, it's about $100 or so

4x4Dalton
08-15-2013, 07:03 AM
It cost right at about $70. That's all the hardware and primer and paint.

4x4Dalton
08-15-2013, 07:11 AM
I will be building another roof rack soon. Different design but will have to add welded areas to it, after a couple years the corners did get loose to the point of having to weld. Ill keep y'all posted as the build goes down.

bulrid8
08-15-2013, 07:41 AM
Has anyone tried the compression connectors on one yet? May hold better then the screw ones.

Sent from my ADR6400L using Tapatalk 2

SeniorGustas
08-15-2013, 12:49 PM
Planning to make another thread for it!? :D im building this one this week! Thanks for sharing!

hondiker
10-22-2013, 09:24 AM
How did you attach your crossbar to the frame itself?

4x4Dalton
10-24-2013, 06:58 AM
I first drilled and sheet metal screwed it to jeep racks but later I used small bolts and conduit holders and bolted it down to rails. It held great. Didn't ever have issues with it loosening up or anything.

4x4Dalton
10-24-2013, 07:00 AM
I have to say over the past couple of years I have been amazed at the response this build has received. Thank you all who have read it replied and possibly used my idea for yer build.

Mudderoy
10-24-2013, 09:15 AM
I have to say over the past couple of years I have been amazed at the response this build has received. Thank you all who have read it replied and possibly used my idea for yer build.

You should build and sell a kit. :patriot:

OGCollard
03-22-2014, 09:46 PM
Thanks for the great idea! Tip on how many coats and what paint you used to make it durable to scratching?

4.3LXJ
03-24-2014, 09:35 AM
Mark, Bear hasn't been on the forum in awhile due to relocating to an area without good internet. If he doesn't respond it is not because he doesn't care.

rabies
04-03-2014, 02:05 PM
cat has ticks lol. i seen a few threads were people used conduit. one guy even welded his. they end up looking nice. i wounder how strong they are if you had to hang off the side for some odd reason?
i havent seen any pics anywhere of anyone taking off the OEM roof rails and mounting/welding a rack to the actualy ceiling.
il have to venture into this task when i get a garage to work in again.
how come no1 ever makes a full size rack?
anyone have the measurements of the roof by chance off the top of their head?

4.3LXJ
04-04-2014, 10:56 AM
I have considered a full size rack when I take the plunge. Trouble is that I don't want one up there unless I am going camping and need it due to wind drag. But if I take the plunge, you can bet it will be full size and hold a lot.

robouden
04-05-2014, 12:22 AM
I did not even welded. Took standard Tule beams and made frame with wood.
https://www.facebook.com/photo.php?fbid=10152253395392969&l=a58334ef6d


regards
rob

bluedragon436
04-10-2014, 12:40 AM
I have considered a full size rack when I take the plunge. Trouble is that I don't want one up there unless I am going camping and need it due to wind drag. But if I take the plunge, you can bet it will be full size and hold a lot.

The one I have isn't full size, but is decent size.. But I'm going to install it where I can easily pull it and store it in the garage when not needed... I just need to either get some more factory cross bars, or pick up some aftermarket bars to be able to mount it..

prerunner1982
04-15-2014, 01:03 PM
for those that don't need a full roof rack. Here is mine using conduit and home made rain gutter clamp mounts.

XjJeepacorn
04-15-2014, 03:54 PM
cat has ticks lol. i seen a few threads were people used conduit. one guy even welded his. they end up looking nice. i wounder how strong they are if you had to hang off the side for some odd reason?
i havent seen any pics anywhere of anyone taking off the OEM roof rails and mounting/welding a rack to the actualy ceiling.
il have to venture into this task when i get a garage to work in again.
how come no1 ever makes a full size rack?
anyone have the measurements of the roof by chance off the top of their head?

I don't have any real great pics right now but this is mine I built it out of conduit and 1/8 metal all the inside supports are welded and the out sides are bolted. Made the light bar too. I also welded it to gutter mounts. I forget who I bought them from they were relitivly cheap :)

5078

Sent from my SGH-M919V using Tapatalk

Rocco83
04-15-2014, 05:48 PM
You weld to/on the conduit? Was it galvanized? If so you're damn brave.

Rocco83
04-15-2014, 06:00 PM
Did you weld onto the conduit? Was it galvanized? If so you're brave haha. I still can't figure out what I want to make my rack out of yet. Thinking I'd rather do the welding route for the strength.

XjJeepacorn
04-24-2014, 04:27 PM
I know I used a resperator and I was in a well ventilated area

XjJeepacorn
04-24-2014, 04:29 PM
The outside is very strong I'm thinking about rebuildibg the insides with dom tube maybe the bottom portion too because I'd also like to make an exo one day