A huge factor to its strength is in the way that it’s fastened to the van. I have a piece of aluminum extrusion that was given to me with a rounded profile on one side and square on the other. It's not readily findable in a google search though. I didn't know this source was out there, and it's a one-day UPS Ground distance from me :). 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. For industrial framing or something in a shop, no biggie. Well it looks killer and it goes without saying that it is HIGHLY modular and with a roof rack that is key. My plan is to not always leave these extra long bars on there though. 3. 7211 views on Imgur: The magic of the Internet. I suspect this is a lighter than steel would be for the same size though i suspect welds are lighter than the hardware. I modeled the end cap in Fusion360, based off the diagram 80/20 provides. I bought some 80/20 from Amazon and a second shipment right from 80/20. Steel hardware 60+ m8 bolts, washers, and slotted nuts add up a bit. 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. DIY Extruded Aluminum Roof Rack - diy post. Thanks. expeditionportal Question Also how has wind noise been with the T Slot Bars? 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. Shipping for me was about $33. 1 year ago. 80/20 T-slot extruded aluminum (aka - the industrial erector set) is very lightweight and in my opinion very strong. Pinterest. There are cheaper materials than ext aluminum. While it is significantly heavier, it was also MUCH Cheaper; and, unfortunately co$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. I've been planning and 80/20 rack build for a while now. But in my case it was about 2 weeks between when I order online and when they shipped it UPS ground. 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. 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. It's probably illegal to use a non certified roof rack in your country. Van Roof Racks Truck Roof Rack Car Racks Truck Bed Truck Camper Truck Storage Awning Roof Diy Awning Roof Rails. The plan is for three cross beams to mount my Yakima Mega Basket. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. 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 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. One of the things I love most about the Extruded Aluminum (8020) material is how strong it is. You never claimed that this was the Cheapest, or Most Expeditious/Convenient. 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. This is a roof rack that is ALMOST all DIY. You can see the process I went through to find a good fit for my Bolt. :). 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. 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). CUSTOM ROOF RACKS! Extruded aluminum roof racks are more flexible and offers more room for adjustments unlike the steel roof rack. 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. I have built many roofracks for different cars over the years and have never spent much on them. The rack has been great so far, and I don't really have any thoughts for changes if I were to do it again. I'm very glad you posted this. For those who aren't familiar with 80/20 extrusions, I'll give a very brief overview. 4th and 5th revisions were for functional testing. Each pair of holes was measured, and they all turned out to be the same distance apart, 120mm between holes. DIY Extruded Aluminum Roof Rack Discover the magic of the internet at Imgur, a community powered entertainment destination. Faster! I build simple racks out of angle steel and I think it would weigh 60-70lbs for a full size rack for a LX. 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. July 2020. I was able to cut the aluminum to rough size with a bandsaw, and used a large belt sander to fine tune the shape. However, in the end i was able to put this rack together for about $700, if i pretend like i didnt buy hardware twice. This gave the surfaces a nice smooth and clean look. Aluminum, extra-wide, basket-style cargo carrier is … I did this roof rack mod over the summer. 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. Ha ha there is A LOT of aluminum in 80/20 too. No need to find smooth ground for a tent. 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. There may not be a weight benefit with 80/20. * carry Yakima skybox and ski rack at the same time. I even opted for the "lite" cross sections that have less aluminum. To line this up, I put a scrap of plywood in the laser and made a laser mark of the outlines. Roof racks dont need to be fancy, just simple and strong. Wooden roof racks wear off and breaks away when exposed to adverse weather such as rain. 95. To attach the cross bars to the roof rails, I used four 10 Series 4 Hole - Wide Inside Corner Brackets. Im a little late posting the thread, but now after several uses, i can attest to it being solid. Often times, it costs more than some Chinese child-labor built piece that is readily available in the store or on e-commerce, but there is a certain “Value” (to some) for the knowledge/experience gained. DIY Extruded Aluminum Roof Rack. I put them in place with my aluminum 80/20 rails to confirm it was a good fit and angle. It's got a complete parts list. 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. That extruded aluminum was something I wanted to try, as I see it often in restroom stall wall applications. 99. This example is for any cars with factory attachment points already available. 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. About: The IDEAWORKS Innovation Suite is part of the Library and Academic Technology department at Washington College in Chestertown, MD. 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