Airmapper's Custom Roof Rack Build

Airmapper

First Fill-Up (of many)
In my last thread I was excited about getting a welder and finally joining the world of fabrication. I can now say my first project is nearing completion.

While my primary reason for needing a welder is Bronco projects, I decided the X would get the first attention, as it would give me a chance to practice on something a little easier, clean metal and lots of welding in more comfortable positions. For the most part though the welding was much easier than I anticipated. I did make a few messes, but considering the thin walled material and some less than superb cuts I worked with, I'm fairly happy. It warped slightly, but I'm a perfectionist, so I can get anal about such things quickly.

About the first of the year, before I knew I'd get a welder even, I started to design what I wanted, and incorporated design features I liked.

Since shipping was not a consideration, I could design for full roof coverage without attachments. Basically it is a hybrid of a Dephep and a Garvin, with some unique touches that make it not exactly like either. My favorite features are I managed to keep the hardware hidden, and keep the entire rack inside the stock bars. It's much less visible from the sides, to the point you may not even notice it, it also does not obstruct the stock bars except where it has to mount.

More photos will come when I permanently install it. I did a test fit today and it was good to go. I even hopped up there and stood on it (I'm a shave over 200lbs) and it was solid, even without the fasteners fully tightened. I'm trying to decide if I'm going to take it to the powder coat shop or work on it some more. It could have more features, but at this point I don't want to detract from the clean looks. I initially planed for optional raised and extended cross bars, but have found they may be unnecessary, as my Kayak J bars will mount directly to the insert rack. If I really want more doo dads, now I know I can always design and build a version 2.0

I also haven't figured out what to do with my CB antenna. I'm not liking it very well anyway as it's always in the trees or I'm trying to get in the garage with it up, so I don't really want it on the rack. I may have to start from scratch on that.

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Airmapper

First Fill-Up (of many)
Thanks guys, now for the rest of the story...

Got my rack back from the Powder coat shop this afternoon. They did a great job. It's the first time I've had anything coated, I love the smooth finish, and the fact it's not scratching up from the least little thing.

And here is the finished project. Maybe a few more tweaks on the mounts, but I'm calling it done. I'm pretty happy with it, of course since I built it I can spot it's flaws, a bit out of square here and there, and a few rough corners, but you can't really tell if your not nit picking.

I included some details on the mounting arrangement because I'm sure you all are curious, and I didn't show it before. This setup is pretty tedious and required some fairly close tolerances, which is probably why I've only seen something like it used on the manufactured Garvin rack. I actually was surprised I held it close enough to work given this is after all my first full on fab project, but I favored this method because it was cleaner looking, I could buy the mounts instead of make them, and it hides exposed hardware.

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KBC

Bought an X
Location
BC
That's sweet, where do you order those mounts from? I've been thinking of making something similar but haven't figured out how I want to mount it.
 

slantyshanty

Bought an X
Location
'Merica (DFW)
Man, that is seriously cool! I would totally have something like that, if I only had a need for it. Seems like I haven't been camping in ages... Hopefully that will change soon.
 

Airmapper

First Fill-Up (of many)
Thanks guys, I'm really glad it turned out well. Although I think I'll keep it to myself that folks think I have a nice rack.....

That's sweet, where do you order those mounts from? I've been thinking of making something similar but haven't figured out how I want to mount it.
Real nice man! Rep given. Those mounts are sweet! Will you share where you got them or is it a design secret?

Ha ha, well I admit I thought about keeping it a design secret, but they are not exactly proprietary or secret. These mounts could be used for so many rack related mounting jobs. Heck during my research on them I found FJ Cruiser guys are using them on their racks. Besides anyone capable of making something like this on their own I encourage to do so, it's been very satisfying to make this and say "I built that" and not just write a check. It was a fun project.

I got the mounts from McMaster Carr, they are called vibration dampening U bolts. (LINK) Note you can get them in stainless as well, if you want to pay $20 each. Zinc coated will hold up well.

The trick to using these is using a strip of padding to compensate for the size difference, as they don't make those U-bolts in Xterra rack tube size. (Which is about 2-1/4"OD) I actually ordered one ahead to make sure it would fit, and for a while used the one by itself to mount my CB antenna. It's a bit loose without a lining to fill it in a little.

Soon I hope I'll have photos of the rack in use. I bought some universal J bars for my Kayak, and found they will mount directly to the rack without needing extra cross bars, so I'm anxious to see how that setup works.
 
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