DIY roof rack *plusnuts*?

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DIY roof rack *plusnuts*?

Postby Ingmire [OP] » November 18th 2016, 3:37am

Ive been brainstorming about a roof rack all week. I have no metal work experience.

My Astro 94 awd ext. has a 'Naked' roof.

I got 4 'closed bar holders' brackets used for 2x4's
- these will be the feet and mounting points to the roof.
4 u-bolts with lock nuts
- I will drill holes for these to mount length wise with the 'closed bar holders'
2 6' galvanized steel pipes 1"
- for the cross bars that will be fastened down with the U-bolts.


I would like to fasten this to the roof with plusnuts.
Does anyone have any input which ones I should buy?

Is there certain areas of the roof that are stronger anchor points for mounting?

Or any other input regarding my design?

Thank you!!!!!!!
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Re: DIY roof rack *plusnuts*?

Postby WoodButcher » November 18th 2016, 1:02pm

https://www.amazon.com/gp/product/B008V ... UTF8&psc=1

https://www.amazon.com/gp/product/B003T ... UTF8&psc=1


Through bolting to the roof ribs is a better alternative but these are the rivet nuts your thinking of.
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Re: DIY roof rack *plusnuts*?

Postby Lumpy » November 18th 2016, 3:58pm

I'm pretty sure that no rack that you could fab together out of parts not made to be a rack will be a structural disappointment AND will end up costing more than just buying a pre-made rack.

Triple that if you are not at all experienced in metal working.

Sometimes the simpler route is, um, simpler.


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Re: DIY roof rack *plusnuts*?

Postby 97cargocrawler » November 18th 2016, 5:15pm

At the very least look into electrical strut for the cross-bars. Home depot, 10ft lengths for like $18. Those will allow you far more options for attaching stuff.

Brainstorm some more. There are at least 5 major roof rack builds on here.
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Re: DIY roof rack *plusnuts*?

Postby AstroWill » November 18th 2016, 5:16pm



Lumpy wrote:I'm pretty sure that no rack that you could fab together out of parts not made to be a rack will be a structural disappointment AND will end up costing more than just buying a pre-made rack.


I'm pretty sure that any rack that you could fab together out of parts not made to be a rack will be a structural disappointment AND will end up costing more than just buying a pre-made rack.

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Re: DIY roof rack *plusnuts*?

Postby Ingmire [OP] » November 19th 2016, 3:06am

Thanx for the replies! Though I don't have metal work experience I have done way too much research on diy racks and Yakima / Thule racks. And I'm convinced the 'store bought' racks are nothing special and a diy rack will be just as structurally sound and easily more so if desired. Though that isn't my reason for making my own. I just enjoy the learning process of making things :)

Had I not already purchased all the material to make my own rack I would have bought the 'Yakima top loader' (I didn't know it existed) which is very similar to what I am doing. It's a bracket attached to the roof with plusnuts
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Re: DIY roof rack *plusnuts*?

Postby Ingmire [OP] » November 19th 2016, 3:09am

Wood butcher

Those are rivetnuts I'm going to use plusnuts.
The plusnuts have a much bigger foot print
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Re: DIY roof rack *plusnuts*?

Postby AstroWill » November 19th 2016, 3:38am

Ingmire wrote:Wood butcher

Those are rivetnuts I'm going to use plusnuts.
The plusnuts have a much bigger foot print


A screen-shot of a partial article doesn't really do much good if you want to read the entire article ;) A link would be much more suitable. Plus nuts.

http://www.pointsunknown.com/blog/2016/ ... -plusnuts/

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Re: DIY roof rack *plusnuts*?

Postby WoodButcher » November 19th 2016, 4:23am

Regardless of which you use to fasten to the sheet metal you are still only on sheet metal. there is no way to increase the load capacity w/o through bolting to the cross members and shimming between them and the tin roof. In fact by putting your load up on 4 or even six of those "feet" you will lessen the capacity because the #250 is assuming the load to be spread out rather than up on feet.
In this post I gave a quick rundown of the rack on my '93.
viewtopic.php?f=127&t=17922&start=340#p910386
The load is spread over almost 8' per side on that track, the rivnuts do little more than keep the loaded rack from sliding and the empty rack down at highway speed. Granted I ran about 12 per side. They don't hold the load itself, gravity does.
I've been in the trades hauling crap on the roof for far too many years and never saw a truck lose a rack, loads yes, but never the rack. Straps and bungee fail long before a properly fastened rack does.
When I bought my '97 it had just the rack mounts and they were caved into the roof from improper mounting locations and having a load on them. It was used for "Carol's Cleaning Service" so I imagine they carried a ladder or two to wash windows. I fixed the mounts and carry much more than most since then.

29946

2112

62609

62601


I would suggest looking up CargoCrawlers rack build. Jack did a beautiful job and documented how the tin roof needs to be shimmed to the crossmembers in great detail. I think he went overboard but then he always does, claims to keep a harem in the roof top tent, I think it's just a blowup doll. Why else would he have onboard air? :lol:
:poke:
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Re: DIY roof rack *plusnuts*?

Postby Ingmire [OP] » November 19th 2016, 6:18am

WoodButcher wrote:Regardless of which you use to fasten to the sheet metal you are still only on sheet metal. there is no way to increase the load capacity w/o through bolting to the cross members and shimming between them and the tin roof. In fact by putting your load up on 4 or even six of those "feet" you will lessen the capacity because the #250 is assuming the load to be spread out rather than up on feet.
In this post I gave a quick rundown of the rack on my '93.
viewtopic.php?f=127&t=17922&start=340#p910386
The load is spread over almost 8' per side on that track, the rivnuts do little more than keep the loaded rack from sliding and the empty rack down at highway speed. Granted I ran about 12 per side. They don't hold the load itself, gravity does.
I've been in the trades hauling crap on the roof for far too many years and never saw a truck lose a rack, loads yes, but never the rack. Straps and bungee fail long before a properly fastened rack does.
When I bought my '97 it had just the rack mounts and they were caved into the roof from improper mounting locations and having a load on them. It was used for "Carol's Cleaning Service" so I imagine they carried a ladder or two to wash windows. I fixed the mounts and carry much more than most since then.

29946

2112

62609

62601


I would suggest looking up CargoCrawlers rack build. Jack did a beautiful job and documented how the tin roof needs to be shimmed to the crossmembers in great detail. I think he went overboard but then he always does, claims to keep a harem in the roof top tent, I think it's just a blowup doll. Why else would he have onboard air? :lol:
:poke:


Thanks so much for the solid input! Going to check out cargo crawlers work now.
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Re: DIY roof rack *plusnuts*?

Postby Lumpy » November 22nd 2016, 3:34pm

Lumpy wrote:I'm pretty sure that no rack that you could fab together out of parts not made to be a rack will be a structural disappointment AND will end up costing more than just buying a pre-made rack...



I guess that should have read "any rack" or "a rack" rather than "no rack". But I'm pretty sure the message got across.


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Re: DIY roof rack *plusnuts*?

Postby AstroWill » November 22nd 2016, 7:41pm

Lumpy wrote:
Lumpy wrote:I'm pretty sure that no rack that you could fab together out of parts not made to be a rack will be a structural disappointment AND will end up costing more than just buying a pre-made rack...

I guess that should have read "any rack" or "a rack" rather than "no rack". But I'm pretty sure the message got across.

:poke:

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Re: DIY roof rack *plusnuts*?

Postby sixsix » November 22nd 2016, 7:54pm

WOW .



Mike
.

Well, after all... what would Banacek say ?... Anyone that condones the actions of the American People during the Storming of the Capitol are as complicit as the Assholes themselves.
But no way does this let the Democrats or the MSM off the Hook.

.
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