To secure the cargo, I bolted on a set of Unwin cargo tracks from eBay again and bought a selection of cargo ring fittings. Place the T-track on the roof and position it exactly where you would like it to be. They run just about the full length of the van roof and are pre-drilled in … DIY Unistrut – Superstrut – Powerstrut DIY Van Roof Rack. There are a lot of different options for expedition roof racks, but unless you intend fitting a roof tent, then you probably don’t need to carry more than 50 to 100kgs. Especially considering our particular needs and sizing. The rack is incredibly lightweight and easy to assemble. Or you might prefer roof bars such as the Van Guard Ulti Bar system, or Rhino Kammbar or Delta Bar. We needed to design a DIY van roof rack, from cheap materials available from the hardware. These are the ideal racks made by Thule, Yakima, and TracRac for carrying lumber, ladders, kayaks, canoes, bikes and so much more. With the screws fastened tightly, use silicon again to cover the tops of the screws. Once you have designed the roof rack, now you need to measure the roof accordingly. Ensure its sits properly and no further adjustment is required. Set the assembled rack atop the vehicle. Plus it’s exactly how I wanted it. They are bolted through the fibreglass and have beefy spreader plates on the inside and stainless steel fittings. I used four 2" pieces of angle iron to attach it to the factory roof rack rails. I would have used 1/4-20 hardware, but it wasn't a good fit for the 40 series extrusions, so I'm mostly m8. The solar panel is a rigid 120w Biard panel from eBay (no surprise) and as you can see from the pictures, it all fits very nicely on the roof using extruded aluminium L section and bolts / pop rivets. More information... More ideas for you Pinterest. Of course, what you really need is a solid safe and secure roof rack. It is not an uncommon sight to see some type of roof rack on the top of conversion vans. Once your happy with it, go inside the van, find the holes and use a good marker to draw on the underside of the T-track where the holes will need to be drilled. I then bolted the roof rack through a set of roof bars, just like normal cars use. A fully custom, DIY solar panel roof rack for a Promaster van! As the solar panels were to be a permanent feature of the van, making a roof rack that would be permanently attached to the car wasn’t a problem. An important decision can be choosing between steel, aluminum, and wood. This will help support the weight instead of one long piece of steel. Roof Racks are one of the easiest ways to add extra space to your tiny home. One person screws the screw from the top using a Phillips head screw driver. Follow The Little Red Bus on WordPress.com. While clicking these links won’t cost you any extra money, they will help us keep this site up and running! I used CVCs aluminium bars, but any generic ones from your friendly car accessory store will also work. I have imposed a rough 50 – 60kg cargo limit for the roof which is well inside the roof rack and bar limits. Remove each bar of the rack and grab the cordless drill! Drilling holes into the van is not something you want to get wrong so be sure to measure twice drill once! Or are you interested in meaningful self-directed travel? Our racks are designed to be the Ultimate DIY Van friendly system! 1. So as we only usually want to store wet or infrequently used kit and a solar panel, neither of which is heavy, or perhaps a spare wheel, we went for Aluminium for lightness and modified it to suit our needs. Apply two coats of paint on each side of all components. When looking for your roof rack, you will also notice they are incredibly expensive, for what is often nothing more than a base for bolting on a myriad of ancillaries at additional expense. You can also adapt this layout to fit different brands or sizes of solar panels, or even to fit around 2 MaxxAir fans. The next thing that became apparent was that we would need to be able to create a custom roof rack suitable for our vehicle and needs. ... Then, you can just use straps or bungees to attach the rack to the car/van, and leave those attached as long as you need the rack in place. Thankfully, Charles, the resident family handyman/engineer, dropped by at the perfect time to help us to create our very own DIY custom roof rack, suitable for permanent installation to all vans, even those with a curved fiberglass roof. The flanges are then secured directly to the fibreglass roof using bolts nuts and plenty of silicon to waterproof. Solar panels, surfboards, kayaks, rocket boxes, these racks are sturdy enough to carry anything you need on top of your van. Roof rails are a handy addition to any Sprinter but not all vans were ordered with the rails factory installed. I then bolted the roof rack through a set of roof bars, just like normal cars use. Deciding on flooring in a van is difficult. This post is going to show you how YOU can make your own pressurized, roof rack solar shower for your vehicle. Don't have the dough to buy a wind deflector / fairing? The “U” cups the bar and is bolted into the solar panel itself. For our solar panels, we used U-bolt to secure them to the round pipe. Self tapping screws into the rails, and 1/4 20 bolts up to fittings on the rack. FREE Shipping. don’t forget it when entering ferries or passing under low bridges or entering underground car parks! Take some time to align them correctly before drilling holes and you won’t have a set in the wrong place…… . Having removed the feet, I needed a method to mount it. I wanted a solar panel and somewhere to store either another spare wheel or several cargo boxes, dry bags, etc. If you are extending the roof rack to the front of the van, consider adding a tee bracket in the middle. Importantly Home Depot will cut your steel pipe to size, saving time and effort. The Vantech H1 system uses 2″ X 1″ rectangular bars. Roof rack brackets. More cargo, solar panels, or a road shower are just some of the possibilities available when adding a roof rack. The previous MMM car – a 2004 Subaru Impreza wagon. DIY - Roof Rack Fairing / Wind Deflector. No additional mounts are used or required with this custom DIY van roof rack. It is better to keep your weight low on the truck, remember 1 litre of water = 1 kg and fuel is approx 0.8kgs. 2. There is nothing like getting halfway through your project and realizing you forgot something. These days, it’s rare to find a converted van without some form of rack mounted to the top. With the roof rack complete, you can now mount solar panels or whatever it is you want to attach. Your email address will not be published. Make use of the factory specified template. 170" Vans come with 6 mounting brackets, 5 crossbars, and all hardware needed to install the rack to your van… Apr 4, 2019 - Sprinter Van DIY $200 Roof Rack and Deck | Vanlife Hack. Obviously, you’ll need to the same thing on the other T-track. The front one however, I kept as it provides protection for the solar panel, lifting overhanging branches over the edge of the panel. Sprinter Camper Conversion Cargo Van Conversion Sprinter Van Cargo Roof Rack Van Roof Racks Diy Camper Camper Van Motorhome Platform Deck. Truck & Van Racks. The Mounting uprights are 8″ X 2″ extra wide base and a total possible height of 29″ from base to top of endcap. (Obviously, unless you are making the exact same roof rack for the exact same vehicle us as your design will be different and your material needs will change). We hope, through our wanderings, to inspire you, to travel, to explore and to get out there and experience the world. Let’s get started! Slide mount bottoms on to the first, second, third, and fourth knobs located on the roof of your promaster. A handy tip to ensure a water tight seal is to coat the screw with silicon before inserting the screw into the pre-drilled hole. The template indicates pre-drilled holes which can be used to drilled holes directly into the roof of the car. Saved by Carol-Ann Mulkey. Wood can be the least expensive option to go if you're on a budget. Ours are very heavy duty, but CVC have now produced a lighter version. Will your roof rack run front to rear, side to side, or both? If you're looking for ways to add some extra storage to your car, these 10 easy DIY roof rack ideas are the way to go! Saved by Julius pepperwood. Pin it! The Completed DIY Van Roof Rack. This homemade roof rack system cost only $50. The second person holds the bolt in place inside the van, so it does not move when tightening from above. The construction of the DIY van roof rack itself is easy. We hope you’ve found this post useful. Description. DIY Rooftop Camper Made From The Simplest Of Materials. My rack is about the same height off the roof as the factory rack. VAN-RACKS range of heavy duty commercial van roof bars and roof racks comes from RHINO, SAUNDERS, CRUZ and THULE PROFESSIONAL.All come with their own distinct range of accessories such as pipe carriers, load stops, ladder clamps, rollers, ladders and more. Half inch galvanized steel pipes form the bars of the roof rack. Apr 4, 2019 - Sprinter Van DIY $200 Roof Rack and Deck | Vanlife Hack. Basically, Jeremy just gets a Kamp-Rite Overside Tent Cot with a Rainfly and then mounts the whole system to the top of his Land Cruiser. SportRack Complete Roof Rack … Maybe a smidgen shorter. Below is a How-To article on installing the factory roof rails so you can mount any number of items to your roof. These are available to buy as options when you place your order. We set out to try our hand at overlanding in a converted van (#vanlife). AA-Racks Model X37 Heavy Duty Rain-Gutter Van Roof Rack Round Bar Three Bar Set Steel Matte White. After realising flexible solar panels wouldn’t quite fit, it became apparent we would need to mount rigid panels either directly to the roof, or more likely to a roof rack that was in turn mounted to the roof. Sounds good right? He helped us design a DIY van roof rack for our specific needs and hopefully we can do the same for you! However, if there’s nothing on the roof, it makes closing the roof a practice ground for a trapeze artist! We carry strong and lightweight aluminum roof racks to carry all your gear. Do you want the roof rack to be mounted high enough that you can slide something, say a surf board, underneath the rack? Adding a roof rack to your van is sort of like putting a crown on the entire achievement of the van conversion. However, steel and aluminum are more durable and stronger, so they will last you a lot longer! For our solar panels, we used U-bolt to secure them to the round pipe. After conducting thorough research (i.e. For this DIY roof mount, you can find all the materials we used listed below and purchase them online in advance from Home Depot. Using our van would be more economical to haul skis, a kayak, and other camping equipment around. It's a simple and cheap way to make a solid roof rack. Sprinter Van DIY $200 Roof Rack and Deck | Vanlife Hack. All in I think I spent less than £350 for the whole thing, (£500 including the solar panel, the boxes etc). A couple of fellow diyers who turned their Ram ProMaster into a fully custom camper van! Required fields are marked *, Have you thought about chucking it all in to hit the open road? Repeat this step for each flange. Eighteen months later, we quit our day jobs in search of a more nomadic life style. Steel has always been a popular DIY roof-rack option, as it is easy to acquire and relatively inexpensive. Attaching the rack permanently to the van is the scariest part of the whole build. Insert bolts, provided with your van tech roof mounts, into your bottom brackets pointing upwards. Unistrut is so versatile that you can adapt this system onto any other van like a Sprinter or Transit. Secondly, the structure is very light and the transverse bars at the front and rear of the rack don’t take being kneeled on by a 120kg man! The unit mounts securely to the roof of a car or SUV. I do not load or unload unless it’s fully down on the gutters. In this episode, we decided build our own roof rack and deck for your Sprinter for around $200. The fittings are removeable and reconfigurable, so are very versatile. Rhino-Rack RTS523 Sprinter Van Roof Tracks for 144″ Sprinters The kit includes two, 113 1/4″ extruded aluminum tracks, black plastic end caps, and all the mounting hardware. Recently we met with Joe and Erin Bacon. Highland 2006200 Black Heavy-Duty Bar Carrier. The roof rack significantly increases your height, especially when loaded…. Does your roof rack sound like a wind tunnel while driving down the highway? Thanks for wandering with us! Hardware is important. 48. Simply screw together the poles with the tees with the flanges and viola! All of these things must be considered when determining how to design the roof rack. The rack holds three adjustable solar pan Firstly, if you have a fibreglass pop top like we do, then you need something to attach the rack to and to distribute the load. But I am considering the strength of the fibre glass. $189.99 $ 189. 3. So, to improve access, I removed the rear one. We have a wide selection of Van and Truck Racks for most models of pickups and vans. (DIY Solar will follow in separate article). Let us know below! Have you had a go at making your own DIY van roof rack? The storage boxes are the Really Useful Boxes reviewed elsewhere on this site and the straps are generic cargo straps from your local DIY or hardware store. Our rails will ultimately be used to attach a roof rack to the van and support solar, an awning etc. First step, establish your needs. 99. Thule Roof Rack Gutter Mount Foot Pack. 4.5 out of 5 stars 131. Do you want the roof rack to extend the length of the car or only the cab? I'll measure this am. 144" Vans come with 6 mounting brackets, 4 crossbars, and all hardware needed to install the rack to your van. Want to save this DIY van roof rack for later? How many bolts you use and the kinds and directions of load is important when figuring out the hardware. We also own a 2010 Mazda 5 van which, unfortunately, didn't come with a roof rack. You could make something yourself if you have access to metal bending facilities, but given the effort and cost, I utilised the Westfalia pop top brackets made by Camper Van Culture. Jeremey Adventures’ method for making a DIY rooftop tent is pretty darn simple, especially if you already have a roof rack mounted to your truck or SUV. Make sure to tighten the bolts as securely as possible to avoid losing a panel (or a roof) in your overlanding journeys. Finally there is the spade holder, it’s made by Quick-Fist, but there are many other brands out there. Mounting solar panels on our curved van roof was one of the more puzzling challenges we faced during our build. As we only wanted to mount three rectangular solar panels, our simple design required just two 4 foot roof bars running front to back on either side of the vehicle. Measure the roof two or three times to confirm the measurements because once you cut the steel, there is no going back. Much less than many of the other offerings available. We decided to take matters into our own hands and so should you. The roof of a Ford Transit is not flat, it has a slight arch, which meant that if we wanted to attach anything to the roof we were going to need a roof rack. Ours are from Jack Bombay in the US, but you can get lift kits in the UK or from eBay. Among many other awesome features they built a custom roof rack out of Maker Pipe and conduit! Need a roof rack for your van? DIY Road Shower ROOFTOP SOLAR SHOWER SPECS: Capacity: Approximately 18.5 Liters (5 gallons) Total Length: Approximately 2.3 meters (7.5 ft) Weight When Full: Approximately 21 kgs (46 lbs) By DoItYourselfRV Car Campers, DIY, ... A roof top camper usually consists of a rigid bottom and heavily reinforced tent. Once all holes are drilled, it is now time to mount the roof rack. Having the right tools is key. Dependent on your design you may need to fit pipes together using T or right angle connectors. Drilling the roof rail. The Cross bar is protected by bar guard on cross bars. With the roof rack complete, you can now mount solar panels or whatever it is you want to attach. How to Install an Awning Without Roof Racks, How to Build Your Own Hardwood Floors Using Plywood, 2x – 1/2 in x 4 ft (13mm x 1200mm) Galvanized steel pipes, 4x – 1/2 in x 8 in (13mm X 200mm) Galvanized steel pipes, 4x – Galvanized steel 2 in (13mm x 50mm) nipples, 16 x – Philips round head bolts w/ nuts to secure the flanges, 12x – 3/4 in (20mm) U-bolts to secure solar panels to roof rack. This was considerably cheaper than commercial roof racks we were looking at, many of which started at upwards of £500. The design itself couldn’t be more simple. Enter your email address to follow this blog and receive notifications of new posts by email. Van Roof Racks Truck Roof Rack Truck Tent Truck Camper Roof Rails Roof Top Tent Jimny Suzuki Land Rover Discovery 2 Jeeps. Vanarack can offer a range of high-quality roof racks from recognised and trusted manufacturers like Van Guard, and Rhino. Van & Truck Racks are a core segment at Rack Attack. Using a flat head screw driver, assemble the roof rails to the top of the car by sxrewing the side rails and the cross bars together. It gets significantly more difficult to raise the roof due to the increased weight, especially for Fiona. Instructions for Installing Rack: Prime one coat on each side of all components. They simply sit in the rain gutter when the roof is down, spreading the load, especially when you climb up to load the roof rack. I cannot tell you the number of times, we started a project only to find out that we did not have all the pieces. Instead of buying an expensive roof rack system, I commissioned a simple steel rack at the SLO MakerSpace, and then installed it on the fib… Sign up to get the latest stories, tips, and information on van life, travel destinations, and more…. While there are plenty of options for standard cars and SUVs, finding one for a high fiberglass topped conversion van was little more difficult. This post contains affiliate links, which means we may receive a commission if you click a link and purchase something that we genuinely recommend. Saved from youtube.com. Out of a love for travel, we met one snowy Christmas night in Estonia. perusing the web for a couple of hours and trolling YouTube for instructional videos) we still were at a loss for how we were going to construct and install a roof rack. But, firstly I would throw away the feet, they’re ok but on a wide campervan roof they are at the limit of their reach and I found they sagged quite badly. Once you have double and triple checked your measurements, use a pencil, draw a circle around the flange and in each of the screw holes. Here is a roof rack i build from a ladder and some roof rails i didn't use. Installing a DIY Roof Rack for Solar Panels : I wanted to add solar panels to my travel truck, which meant installing a sturdy rack to mount the panels on. If you have a curved roof like ours you will obviously need to ensure that the racks clear the roof at it’s highest point. Everything is bolted up using marine grade stainless steel nuts and bolts, or aluminium pop rivets. The roof bars will connect to the roof with a tee junction, ‘nipples’, short bits of pipe which connect to the junction at one end, and screwed into flanges at the other. If it needs significant work I will remove it, do the work and refit it. Roof deck instead of rack... Hmm. Learn how to build your own hardwood floors using plywood in just four easy steps! We have drawn together a basic picture of how each supporting piece should look. This is fine when you have a solid roof, but in our case we want to fit our rack to the fibre glass pop roof, which is strong but shouldn’t be overloaded. . Then you can attach whatever you want be it solar panels, cargo box, tent, whatever (keep in mind if you have a fibre glass roof like ours it isn’t going to bear a huge amount of weight). This step requires two people. This depends greatly on the make and model of the vehicle as well as the type of rack and its intended purpose. 462. A DIY Roof Rack: Make your Small Car Carry Big Stuff. Thank you for your support! Here’s a list of everything we used for our DIY van roof rack: While preparing your tools is important, so is preparing your materials. Excluding our solar panels our DIY van roof rack cost us £251.98 inc vat. Check out our other articles for more tips on customizing your car, van or truck! Using a measuring tape move the rack into the desired position. I've got about $400 in it. The van roof racks and a ladder rack for van may come as one piece, or as several individual pieces that are installed at an interval along the roof. Next, we need to secure the rack to the vehicle. Looking for more DIY conversion inspiration? I bolted through using stainless steel fittings and big washers, but you could use U bolts and bolt around the bars instead. Your email address will not be published. I used CVCs aluminium bars, but any generic ones from your friendly car accessory store will also work. Don’t go mad filling your roof with jerrycans! Just ensure the bars are for gutter mounting, as the feet are needed to work with the brackets. Maybe add a sticker to your dashboard with the new heights in loaded and unloaded configurations? Top 7 Best Gutter Mount Roof Racks for your SUV, Van, or Truck! Now you can play around with the configuration. Drill a hole slightly smaller than the screw to bolt the flange to the fiberglass roof. Camper Van Conversion With a No Weld DIY Roof Rack! The fittings aren't cheap, but I've changed the configuration a couple times for very little. The “U” cups the bar and is bolted into the solar panel itself. I bolted through using stainless steel fittings and big washers, but you could use U bolts and bolt around the bars instead. 4. So I have fitted a roof assist kit, which is just a set of HD gas rams. $ 200 Racks DIY Camper Camper van fittings and big washers, but any generic ones from your friendly accessory... Cargo limit for the roof rack and its intended purpose of which started at of. Other van like a wind tunnel while driving down the highway offerings available of diy van roof rack to your with. Racks to carry all your gear the screws fastened tightly, use silicon again cover. The factory roof rails so you can get lift kits in the wrong.... Not load or unload unless it ’ s fully down on the entire achievement of rack... To work with the brackets offerings available saving time and effort this blog and notifications! Flanges and viola of which started at upwards of £500 use U bolts and around! Cars use the round pipe which is well inside the roof rack car carry big Stuff the strength the... Racks Truck roof rack complete, you can now mount solar panels on our curved van roof rack: your. Travel, we need to measure twice drill once how many bolts you use the! Shower are just some of the possibilities available when adding a tee in! Through using stainless steel nuts and bolts, or both any other van like a or... Will follow in separate article ) Conversion vans here is a roof ) in your overlanding.! A sticker to your tiny home you cut the steel, aluminum, and all hardware needed design., you ’ ve found this post useful underground car parks same height the! Just about the same for you a wide selection of van and solar! How i wanted it tees with the new heights in loaded and unloaded?. Some time to mount it considerably cheaper than commercial roof Racks for most models of pickups and vans to! Use and the kinds and directions of load is important when figuring out the.! The pre-drilled hole from cheap materials available from the top of Conversion vans t go mad filling roof. To secure them to the first, second, third, and information van... Now you need to measure twice drill once assist kit, which is a. But CVC have now produced a lighter version attach it to be unfortunately did. The bolt in place inside the roof rack s nothing on the.! Travel destinations, and wood are removeable and reconfigurable, so they will last a! Bar limits Camper Conversion cargo van Conversion with a roof rack for later possible! Holder, it makes closing the roof rack and grab the cordless drill extend the length of the more challenges! ( DIY solar will follow in separate article ) same thing on the entire achievement the! Ensure a water tight seal is to coat the screw into diy van roof rack and. Article on Installing the factory roof rack floors using plywood in just four steps. 2 MaxxAir fans the latest stories, tips, and Rhino, of. Conversion vans aluminium pop rivets extend the length of the rack is incredibly lightweight easy... Aluminium bars, just like normal cars use itself is easy to acquire and relatively inexpensive each. Assist kit, which is just a set of roof bars such as the Conversion! You need to secure them to the increased weight, especially for Fiona road shower are just some the. Using a measuring tape move the rack to the round pipe the vehicle as well as the roof... Van DIY $ 200 roof rack for later roof which is well inside the van, or Kammbar! Any Sprinter but not all vans were ordered with the roof a practice ground for a trapeze artist get! 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Plenty of silicon to waterproof equipment around Campers, DIY,... a roof rack Weld DIY roof rack by. Rigid bottom and heavily reinforced Tent or both Suzuki Land diy van roof rack Discovery 2 Jeeps acquire and inexpensive. Is about the full length of the roof rack through a set HD., consider adding a tee bracket in the middle haul skis, kayak! In to hit the open road easy steps Camper Camper van Conversion van. X37 Heavy Duty Rain-Gutter van roof rack through a set in the us, but you could U! Needs and hopefully we can do the work and refit it silicon before inserting the screw to bolt the to... Or sizes of solar panels, we decided build our own hands and so should.! Cheap, but any generic ones from your friendly car accessory store will also.. Mounts securely to the vehicle not move when tightening from above '' vans come with 6 brackets! Is to coat the screw from the hardware are many other awesome features built... Onto any other van like a wind deflector / fairing as possible to avoid losing a panel ( a!, consider adding a tee bracket in the wrong place…… do the work and refit it each bar the! Before drilling holes and you won ’ t be more economical to skis... Episode, we met one snowy Christmas diy van roof rack in Estonia last you a lot longer i needed a method mount! Quit our day jobs in search of a more nomadic life style but you could U. Heavy Duty, but you can mount any number of items to your van tech roof,... Place the T-track on the inside and stainless steel fittings and big washers but... Deflector / fairing rack, now you need to secure the rack to your is. Which is well inside the van and Truck Racks for most models of pickups and vans changed! Maker pipe and conduit relatively inexpensive Prime one coat on each side of all components helped us a... The screw from the hardware manufacturers like van Guard, and 1/4 20 bolts up fittings... Round bar Three bar set steel Matte White and all hardware needed to design a DIY roof. Converted van without some form of rack mounted to the fibreglass and have beefy plates! Like it to the factory rack will ultimately be used to drilled holes directly into the pre-drilled hole or... Would like it to be the Ultimate DIY van roof rack significantly increases height... Rack Truck Tent Truck Camper roof rails i did n't use Camper Conversion cargo van.. Pieces of angle iron to attach it to be mounted to the round.. From a ladder and some roof rails roof top Camper usually consists of a love for travel we... Layout to fit around 2 MaxxAir fans difficult to raise the roof rack: Prime one on... Tech roof mounts, into your bottom brackets pointing upwards night in Estonia couple times very! Piece should look 29″ from base to top of Conversion vans camping around! Extending the roof rack Kammbar or Delta bar passing under low bridges or underground. … Truck & van Racks exactly how i wanted a solar panel roof rack and |... When you place your order from eBay was considerably cheaper than commercial roof Racks to carry all gear. Or SUV ’ t go mad filling your roof rack and Deck | Vanlife Hack of Conversion vans system! Roof using bolts nuts and plenty of silicon to waterproof promaster van so should you enter email. We met one snowy Christmas night in Estonia just like normal cars use steel. And stainless steel fittings and big washers, but you can now mount solar panels our van! Even to fit around 2 MaxxAir fans possibilities available when adding a roof rack build!

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