- Location
- Ashburn, VA
I wanted a simple roof rack that fit within the stock roof rails. I didn’t want a basket that added height, and didn’t want to spend the money for a DepHep or Gobi. I couldn’t find anything that met the size I was looking for so decided to make my own. I made this one for a little over $100
This is 62” long and the inside width of the stock rails is 33”.
Parts List
1-1/2 in. x 14-Gauge x 72 in. Zinc-Plated Slotted Angle - 2 of these, $18.28 each
1/2 in. x 10 ft. Electric Metallic Tube (EMT) Conduit - 5 of these, $3.32 each. I wanted a relatively narrow space between the cross bars so used 14 total. At 33” each, I could only get three per each 10ft piece of conduit. Unfortunately more leftover scrap than I would like, but no other way to get the size roof rack I wanted.
1/8 in. x 3/16 in. Aluminum Rivets (50-Pack) - 1 pack, $5.98. You’ll be six rivets short if you don’t destroy any during the fabrication. I bought another pack. I’ll use them for another project so didn’t count it in the cost breakdown.
1/8 in. x 1 in. Zinc-Plated Fender Washer (100-Piece) - 1 pack, $9.68. So, I couldn’t find a large pack of 3/16 x 1 inch fender washers, only a small bag with three. Since I needed four of these per each cross bar, I decided to buy this pack and drilled them out to 3/16 to fit the rivets. A little bit of a PITA, but the fenders are needed as the rivets aren’t big enough for the holes in the slotted angle iron.
#6 Nickel Plated Finishing Washer (100-Piece) - 1 pack, $5.25. Stainless steel is less expensive, but again I couldn’t find a large enough pack for what I needed, four per each cross bar again. You can do without these, but I added them to make a smoother finish. Without these, the rivet sticks up just a hair more, it’s pretty flush when you add these.
1/2 in. 2-Hole Electrical Metallic Tube (EMT) Straps (4-Pack) $1.11 / 1/2 in. Electrical Metallic Tube (EMT) 2-Hole Straps (25-Pack), $5.24 - 1 pack each. You’ll use two per cross bar.
Nilight 90020B 2-Pack (Standard) Mounting Bracket - 3 of these $9 each. There are two per pack, I used these to attach the roof rack to the stock rails. I used some 5/16, #18 x 1 inch hex bolts and nylock nuts to attach the rack to the brackets.
Assembly photos:
I used vise grips to hold everything in place while crimping the rivets.
Close up of the finished rivet side. This will be the topside when installed.
Primed:
Painted:
Here's install photos. I could have made this a hair wider, maybe 33 1/8. I attached everything on the driver side first, then on the passenger side noticed the brackets aren't quite at 90 degrees. Had to rotate them a bit inboard to attach to the angle iron. Not a big deal, just something to consider if you make one.
Pretty satisfied with how it sits. We'll see how it works, I'll be adding my Yakima ski box soon.
This is 62” long and the inside width of the stock rails is 33”.
Parts List
1-1/2 in. x 14-Gauge x 72 in. Zinc-Plated Slotted Angle - 2 of these, $18.28 each
1/2 in. x 10 ft. Electric Metallic Tube (EMT) Conduit - 5 of these, $3.32 each. I wanted a relatively narrow space between the cross bars so used 14 total. At 33” each, I could only get three per each 10ft piece of conduit. Unfortunately more leftover scrap than I would like, but no other way to get the size roof rack I wanted.
1/8 in. x 3/16 in. Aluminum Rivets (50-Pack) - 1 pack, $5.98. You’ll be six rivets short if you don’t destroy any during the fabrication. I bought another pack. I’ll use them for another project so didn’t count it in the cost breakdown.
1/8 in. x 1 in. Zinc-Plated Fender Washer (100-Piece) - 1 pack, $9.68. So, I couldn’t find a large pack of 3/16 x 1 inch fender washers, only a small bag with three. Since I needed four of these per each cross bar, I decided to buy this pack and drilled them out to 3/16 to fit the rivets. A little bit of a PITA, but the fenders are needed as the rivets aren’t big enough for the holes in the slotted angle iron.
#6 Nickel Plated Finishing Washer (100-Piece) - 1 pack, $5.25. Stainless steel is less expensive, but again I couldn’t find a large enough pack for what I needed, four per each cross bar again. You can do without these, but I added them to make a smoother finish. Without these, the rivet sticks up just a hair more, it’s pretty flush when you add these.
1/2 in. 2-Hole Electrical Metallic Tube (EMT) Straps (4-Pack) $1.11 / 1/2 in. Electrical Metallic Tube (EMT) 2-Hole Straps (25-Pack), $5.24 - 1 pack each. You’ll use two per cross bar.
Nilight 90020B 2-Pack (Standard) Mounting Bracket - 3 of these $9 each. There are two per pack, I used these to attach the roof rack to the stock rails. I used some 5/16, #18 x 1 inch hex bolts and nylock nuts to attach the rack to the brackets.
Assembly photos:
I used vise grips to hold everything in place while crimping the rivets.
Close up of the finished rivet side. This will be the topside when installed.
Primed:
Painted:
Here's install photos. I could have made this a hair wider, maybe 33 1/8. I attached everything on the driver side first, then on the passenger side noticed the brackets aren't quite at 90 degrees. Had to rotate them a bit inboard to attach to the angle iron. Not a big deal, just something to consider if you make one.
Pretty satisfied with how it sits. We'll see how it works, I'll be adding my Yakima ski box soon.
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