Building my own Expedition Roof Rack

Well, as some of you may remember me saying, got myself a welder, so started to play, first I made some light guards, and then I got another new toy – a 16 tonne hydraulic tube bender….so wondered what I could try and make, and decided on an expedition type roof rack. So got some steel tubing in with a 3mm wall and started to play.

Had Sunday free, so measured up a frame…

then made another identical frame and started putting it all together….

Then time got the better of me, so hopefully will get it finished next weekend.

Not bad for again my first attempt at something I ain’t done before if I do say so myself – even though its not finished yet!!!

That is lookin really good so far

Looks good, very good, its making me think about doing my own one....

Cheers guys, to be honest, its not that bad to build, especially now I am getting to grips with my mig welder and pipe bender.

Only thing is trying to measure it to fit the roof, as it ain't the lightest of things to lift, so always need another pair of hands when trying it up on the roof for size etc

Looking really good,
You might just have a waiting list once that 1's finished, I would recommend doing the gutter mounts next before you put to much weight on it tho.

Are those spokey dokeys on the bike?

mrnice said:

Are those spokey dokeys on the bike?

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What can I say....yup biking on dark Somerset roads, even lit up like a christmas tree, I still got knocked twice.....so am trying everything to light myself up wouldn't care, my lights are brighter than the xenons on the disco!!!!!

Crofty said:

Looking really good,
You might just have a waiting list once that 1's finished, I would recommend doing the gutter mounts next before you put to much weight on it tho.

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Might have to order in more steel then...

Yeah, am going to do the gutter frame next and get that fitted on the frame I have already done, then its just putting on the strengthening bars and cross members...sounds easy when you say it quick

StuRox said:

Well, as some of you may remember me saying, got myself a welder, so started to play, first I made some light guards, and then I got another new toy – a 16 tonne hydraulic tube bender….so wondered what I could try and make, and decided on an expedition type roof rack. So got some steel tubing in with a 3mm wall and started to play.

Had Sunday free, so measured up a frame…

then made another identical frame and started putting it all together….

Then time got the better of me, so hopefully will get it finished next weekend.

Not bad for again my first attempt at something I ain’t done before if I do say so myself – even though its not finished yet!!!

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but every things just guna fall straight thru it???? :bounce:

Nah, that's what the roof is for

StuRox said:

Nah, that's what the roof is for

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:doh: sorry my bad, i retract my earlier comment

Well, just thought I would give an update, as spent some more time working on this project....as this is what it looks like now....



Slowly getting there

very very nice..

looks great stu,but looks bloody heavy...

DAZ

Its not too bad, I can still lift it.....just.......but its bloody strong.....

And too be honest based it on the original expedition rack, so can't be any heavier than that....

You would definately make a fortune if you make them to sell, fantastic work so far, put me no.1 on your list to buy one

This is looking really good. Can't wait to see it on the vehicle. What diameter tube are you using? And so far, what is the total length used as it looks like metres and metres lol.

Are you putting spot mounts on the front?

Cheers mate, that means a lot coming from you as love the work you have been doing with the hornet.

When I looked at the original racks they used anything up to 25mm with a 3mm wall, so i decided on 19mm with a 3mm wall as reckon this would be stronger and resist bending etc more.

As it stands now, I have gone through 30 meters and i would like a few more supports along the base of the rack as then gives the option of putting on mesh, and min order is 2 lengths of 7.5 meters so will have plenty more to play with. Also really chuffed as haven't wasted any given this is my first rack

Yeah, my spots will be going on the front, and will be taking off my light bar, that's why I shaped the front lower bar like it is...still deciding on the amount...4 or 6....will also be putting a couple of brackets for rear lights...and even looking at side mounted lights for when out camping etc....can't have enough lights

StuRox said:

can't have enough lights

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Thats very true

Dr_evil said:

Thats very true

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Plus a second battery to power them

Although the way I am going might need a third....