Building my own Expedition Roof Rack

Dr_evil said:

Get some 150w KC Daylighters thats what I'm running and they're ridiculously bright

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Was also looking at the 'roo' lights but its the cost of them, I know they are bright, but its a lot for a couple of lights......

I bought mine second hand paid £160 for 4, prolly about £180 inc delivery

StuRox said:

Back to business, as it was a nice morning, got the rack out for a better pic to tease you guys......

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Great perfect work, I personally dislike powder coating.
Difficult to recover when is damage, .... think about it.
.....To be continued op2:

Just ordered some more steel tubing - another 15 metres and found out its not 19mm with a 3mm wall that I am using but 21.3mm with a 3mm wall...but its the smallest diameter tubing they do with the 3mm wall so reckon it will be the toughest to withstand knocks etc

not half looking the business there Stu...

DAZ

Its always surprising how much steel goes into a product such as a roof rack, explains why they are soo expensive especially when you add labour and profit into the equation.

I like what you have done. its a shame you dont have access to a roller machine as you could have rolled a long curve to match the front roof line just above the windscreen.

As for coating, powder coat may be cheaper than you think and if its saved you money so far doing it yourself, then I would say go ahead and do it. You will get a lot of pleasure from it looking nice!!

more photos of it on the disco please !!!

Well I now have another 15 meters of tubing in the garage.....plus the 3mm steel for the brackets....just got to find some more time now to finish it off completely, as I wanted to get all of the curves etc done at the weekend so now its just cutting straight bits to weld into place.

One thing though from fellow welders - I reckon it will be easier to weld on the brackets to mount onto the gutter rail with the rack on the roof. My question is it just the earth's I need to disconnect from the batteries in the disco to stop things going bang Not sure if I need to disconnect, but better to be safe than sorry I reckon....

Know what you mean about a roller, but have shaped the front quite nicely I think, seem to sit well on the front, and will look better once the spots are fitted on.

Off disconnect the battery when welded for to its calm.

Ive been inspired by your roof rack to make my own but im just curious, how do you intend to mount it onto the land rover?

Ive been looking for a pre-made gutter mount but cant find any and I havent seen any designs that people have home made that I think are very clever.

By the way fantastic work so far, really very impressed with your work!!!
Will

Thanks for your comments

G223 said:

how do you intend to mount it onto the land rover?

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Grit, spit and whole load of duct tape :bounce:

To be honest I have a few ideas spinning around in my head, and will see which one works out best...but involves yet more steel, oh and a few bolts

StuRox said:

To be honest I have a few ideas spinning around in my head, and will see which one works out best...but involves yet more steel, oh and a few bolts

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........ few ideas

something like the 2nd to last one is what I had in mind, as simple and effective - normally the best way

The red discos roof rack is a better mount as it spreads the load across the whole length of the gutter. Remember that the roof and gutter are one pressing in steel on the disco so you have a joint underneath that needs to be taken care of.

The only issue with that type is that it is a little untidy. The Third picture is more akin to the safety devices original. It is neat and tidy and won't spoil the look of you r nice rack.

Well, got the 'rack' part all finished tonight....





Just need to mount it on the Disco now for the gutter brackets to be welded in place and then need to put on the light brackets front and back, a bit of sanding down then a couple of coats of paint and jobs done

Bloody amazing. So how much do you think it cost you including time? More importantly whats next?

topnotch work there fella have you noted all your measurments

Thats a cracking sledge. Roll on winter

Cheers guys, thought about 4 wheels and an engine, its that bloody big and strong... just under 40 meters of steel.....

excellent mate,bit of a difference to your light guards eh,well done Stu,great work...

DAZ

Well, got the sanding done, light mounts on and the first coat of rust proof paint





Just need the weather to last to the weekend so I can get the gutter mount brackets made, then can get the final coat of paint on, and jobs a good one