Building my own Expedition Roof Rack

This is what I am after



Found a place in America that does it - classed as PolyMax overlapping Poulty/Kennel Flooring

Here is their website: PolyMax Overlapping Poultry/Kennel Flooring - FarmTek

But cannot seem to find anything similar in the uk

Looks the business that .. have a look at this google search page, think it'll be more expensive mind!
fibre floor grating - Google Search

StuRox said:

This is what I am after

Found a place in America that does it - classed as PolyMax overlapping Poulty/Kennel Flooring

Here is their website: PolyMax Overlapping Poultry/Kennel Flooring - FarmTek

But cannot seem to find anything similar in the uk

Click to expand...

just try a google search for ""mesh flooring grp poly" and it returns a good few options, how about this?
if you got heavy enough duty stuff, you could always demount it and use it as waffle boards when you were really ion the sh1t

Cheers guys, that helps me a lot, as now I can search around those ideas - was struggling on what it was called

mmmm, is a bit pricey that stuff.

I know I can just whack on a 1mm thick sheet of steel for about £20 but I have been told that if you have a solid covering it can act as a wing and try and take off hence the thought of covering it with some sort of grille.

I could try and cut down the sheet steel into strips and then do like they do on the D3 racks in a chevron pattern...but leave the black parts open to help the wind get through

StuRox said:

mmmm, is a bit pricey that stuff.

I know I can just whack on a 1mm thick sheet of steel for about £20 but I have been told that if you have a solid covering it can act as a wing and try and take off hence the thought of covering it with some sort of grille.

Click to expand...

I put aluminum reef 2мм. and have no problems.
See here: http://www.landyzone.co.uk/lz/f8/my-project-land-rover-discovery-300tdi-171282-5.html

publication #47 Good luck

Could you show a photo of the pipe bender you use? There are none of these racks around where I live and I've been having a fantasy of building a roofrack like this.

Where are you??

Just google 12 tonne hydrolic pipe bender and you will see what i am using...quicker than me going into the garage and taking a photo of it, as having the night off on the sofa tonight, plus its ****ing down.....

mate... AWESOME! the rack, and the autobot head. giving me ideas for my bonnet now... i'm debating converting a tranny van rack to fit, as can get one for free

Cheers Discomark - yeah go for it - whats the worst that could happen

AS for the 'Mark 2' rack......here is a progress pic



The hard work is now mostly done, as the main frame's are now done, just need to join them all together.....

StuRox said:

I have been told that if you have a solid covering it can act as a wing and try and take off

Click to expand...

It's a Discovery!! It has all the aerodynamics of a brick.

I like your second rack, that seems to be a very neat solution.

Its not gonna be as tall as that jig is it ? that looks bigger than the old one!

alexdon said:

It's a Discovery!! It has all the aerodynamics of a brick.

I like your second rack, that seems to be a very neat solution.

Click to expand...

The Disco, maybe, but I don't want the rack departing the roof on a journey if its empty , plus the solid floor doesn't give you any tie down points

Dr_evil said:

Its not gonna be as tall as that jig is it ? that looks bigger than the old one!

Click to expand...

Yes and no, the bottom rail is currently sitting on the 'gutter rail' if that makes sense, so that rail will be lifted up with the brackets that fixes it onto the gutter. The top of the front of the jig is slightly lower than the roof rails so that when I put it all together the rack will sit flush with the rails, making it as low as possible, so reckon it will sit a lot lower than my last rack and about 10cm off the roof to allow the rear sunroof to open properly with a couple of cm's spare

If i used a roof rack I'd go for one of them Baja ones and yes I understand what you mean haha

Looking good there matey.

Cheers bud, by the way, the light bar will def be coming off once this is made and coated, so let me know if you are still interested, will probably be available in a few weeks

Awesome been thinking about buying a roof rack but building one seems like a much better idea if not alot cheaper (her indoors will b happy)

Well 'MK2 rack' is now taking form....just got to attach the top rail and then do the wind deflector and floor bars and then should be ready for powder coating soon



Also, have found out that its called 'weld mesh' that I am after, and found a local company that supplies to offices etc and they are checking to see what 'left overs' they have that I can piece together for a floor

looking very good

Well, got a bit more done last night on 'mk2'...






You can see where the roof rails will now sit, and also I have made the floor a bit more dense as I found with the last one it was only good for 'large' items, and hopefully I will be sourcing some weld mesh to sit on the this one, so this way I don't need to go too thick a gauge to stop bending/sagging