DIY Roof Crossbars for Factory rails

[masso Senior Member Find all posts View Profile Close masso]

Even the El-Cheapo Multi-fit jiggers are nearly 200 bucks! After all... it aint rocket science. About 35 bucks and an hour or two with a similar quantity of stubbies will get this one done.

Ingredients
2 x 1 inch square section aluminium. 1.2m long.. from local metal supplies
1 pack 75mm bolts 3/16
1 pack end caps 1 inch
2 packs 75mm mending plates.
2 packs 3/16 wing nuts
1 can flat black
Total cost..about 35 bucks!!!

Piccies as below... but pretty simple and works a treat!
http://i220.photobucket.com/albums/dd15 ... 4240-1.jpg
http://i220.photobucket.com/albums/dd15 ... CF4241.jpg
http://i220.photobucket.com/albums/dd15 ... CF4254.jpg

http://i220.photobucket.com/albums/dd15 ... CF4256.jpg
http://i220.photobucket.com/albums/dd15 ... CF4259.jpg
http://i220.photobucket.com/albums/dd15 ... CF4263.jpg

[Hutch Addicted PP Member Find all posts View Profile Close Hutch]

mate i have some Thule ones that i would happy to let go for 100 bucks and lap around the block in the OME suspended prado to check the ride.

[masso Senior Member Find all posts View Profile Close masso]

Hey Hutch,

Most welcome anytime to check out the OME. drop me a PM with some numbers and i'll give you a call.

Rick

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Masso don't want to rain on your parade but be really really careful. If you have used 25x3 aluminium box or thinner it will probably not support the rated load of the longitudinal bars over time. A quick calc shows that it will deflect about 7mm in the middle with 50kg on it static load. That means when you drive they will flex up and down and will eventually fatigue and fail. Who knows how long because that depends on how much flex and which grade of aluminium you have used.

The rated load takes into account dynamic forces likes bumps (shock loads) and wind load etc. I think the 25 square aluminium is just too light for this duty. If you look at the Rhino heavy duty bars they are very sturdy and simply supported at each end they don't bend when I stand on them.

I don't have the longitudinal bars on my 120 but got sick of the process of fitting the Rhino rack supports and seals and bars etc everytime I wanted to fit my existing roof rack off the 90. I made some spacers out of 25 x 10 6000 series aluminium that are now bolted onto my roof permanently which gives me the weather seal and also a set of tapped holes to bolt the rack directly to (via an ARB fitting kit). The plates are flush with the strip in the roof unlike the Rhino parts and I am very happy because it takes less than 10 minutes to fit the rack instead of the 30+ that I used to go through fitting the Rhino racks and then the roof rack the whole time being anxious about the rubber seals being damaged or not fitting correctly.



Not saying don't DIY but make sure it is fit for purpose, ok? Any questions feel free to pm me.

Michael

[Novice Lurker Find all posts View Profile Close Novice]

mate i have some Thule ones that i would happy to let go for 100 bucks and lap around the block in the OME suspended prado to check the ride.

Hutch - I could be interested - got any pics?

Pete

PS - sorry standard suspension.

[Hutch Addicted PP Member Find all posts View Profile Close Hutch]

They look like option 2 in this photo, they sit on top of bar and their is a rubber strap that wraps around the toyota bar, pretty much fit any roof rail.
http://www.thule.com.au/vehicleguide_de ... l_id=87198


###SOLD###

[Novice Lurker Find all posts View Profile Close Novice]

They look like option 2 in this photo, they sit on top of bar and their is a rubber strap that wraps around the toyota bar, pretty much fit any roof rail.
http://www.thule.com.au/vehicleguide_de ... l_id=87198

Hi Hutch

Have PM'd.

Pete

[masso Senior Member Find all posts View Profile Close masso]

hi Michael,
Thanks for that... another piece of valuable info from the forum! In actual fact... the reason i decided to DIY, was that the only thing i really need to carry on the roof, is my folding gazebo... just a bit long to get inside with passengers. Hence i didnt want to spend 3 times as much on the racks..than i did on the gazebo! All up weight about 10 kg max.. so will take your advice and go get some "real" racks should i contemplate doing some "real"carrying on the roof. I wanted something quick to throw on and off and just to use for short runs with Gazebo attached.. and yes.. they howl in the wind.. so will only be rarely used. Good advice tho.. thanks Michael.