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Discussion Starter #1
Wanted to share some of my ideas and experiences while designing and building a cargo rack. Factors that are important to me as this build unfolds are: low cost with no sacrifice in quality, DIY, no welding, maximum usable space on roof, an expedition / safari look and ability to add or change what type of cargo it will carry.
Starting with 1 1/4" EMT for the top and bottom loop rails. UniStrut for the cross members and vehicle attachment points. Still working out the bottom of the basket. Likely will be a metal grid pattern. Currently top and bottom loop railing are connected (two separate loops). Cross members are installed. Just started rubbing down the rails with steel wool. Then on to sealing joints internally with silicone, rubber washers were needed and then on to primer. Attached photo is of the bottom front railing.
More photos are coming ...
http://www.jeepcommander.com/forums/attachment.php?attachmentid=29402&stc=1&d=1513904963
 

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Looks like a lot of work and can't wait to see the results. Makes me glad I got my Safari rack for $100 on CL and all I'm going to do is paint it with bed liner.
 

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Discussion Starter #4
update on cargo rack

Update: Most of the parts are fabricated. Just finished dry fitting everything. Now taking it all apart so parts can be filed, metal edges cleaned up, and ready for primer. All bolts are 3/8" x 1 1/2" or 2". The large panels with metal grids are a local find at Lowes. Thought it would work great for the bottom of the rack. Still working out several options on the sides or what I'm calling the risers. Just not sure which way I want to go.
 

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Update on the rack: Had a slight change in plans. Had a fellow overlander offer some welding work. So the risers have been welded to the top and bottom 1 1/4" tubing hoops. The biggest disadvantage I had with this design was the tube couplers with 4-3/8" set screws per ea. coupler. So these were replaced with #10-32 x 3/8" flush hex screws. Giving a very clean look that I can live with. Cleaning up the welds are next ...
http://www.jeepcommander.com/forums/attachment.php?attachmentid=29962&thumb=1http://www.jeepcommander.com/forums/attachment.php?attachmentid=29970&thumb=1
 

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Looks great. I would copy it, but it would never get in the garage.... my satellite radio antenna scrapes as it is.
 
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