Right, Ive decided I cant afford a Safety Devices roof rack, so Im going to make one. When I first saw Urban Panzer's Disco, I fell in love with it, and the roof rack too (dont get me started on his ARB bumper/winch setup)!

Anyway, Im quite good at this fabricating malarcky, but my Dad is even better. Ive sent him the specs and he reckons we can knock one up easily. However, he suggested making it out of stainless steel instead of my idea of galvanising and powder coating.

I just thought Id ask if anyone has used stainless steel for a roof rack before? I would imagine it would weigh as much as the car, or certainly more than normal mild steel.

And, has anyone any ideas or comments from making their own racks? Is it so much hassle to do right that buying an SD one is the preferred route. I remember Nick saying how hard it was to get hold of in the first place, hence me contemplating fabricating a close-as-dammit replica.

Oh, and if it turned out ok, would anyone else want one? My Dad is quite cheap to run, a coffee here and there, eats buns periodically etc. He is currently costing up making one so I can get back to you all on that.

What year is your dad? I have the 1940 model and its costs a sodding fortune to maintain....and the insurance!!!!!!!

The problem with this sort of fabrication project is that everyone wants one, but doesn't want to pay for one. Nice little side income if you are prepared to do it properly though, so don't be put off.

WSLR said:

The problem with this sort of fabrication project is that everyone wants one, but doesn't want to pay for one. Nice little side income if you are prepared to do it properly though, so don't be put off.

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Well, Im more interested to hear about peoples experiences or advice regarding building your own rack, than actually making a business out of it. Im sure a small fabrication firm could make it more financially viable than me.

If someone happened to want one, should I make a decent one, then they would have to pay - or not have one. Im not messing about with that. Ive seen a 'new' tubular rack for Discos on eBay, but I know who makes them so I wouldnt touch it with a barge pole.

The "do I build it out of stainless steel?" question is also an answer Im looking for too. Never seen a stainless rack, there must be a reason.

Gotta be the weight... Years ago I bought a stainless steel parrot cage off e bay. Looked nice and I thought "stainless steel.. must be good ". Got it moved by Parcel force. They charged me a fortune. Turns out it needed two people to lift it ! Must be about the same with a roofrack.. would be a nightmare getting up on the roof.

I used to work for a coachbuilders that repair the big artic trailers that the supermarkets shift food around in.

The rear ends are made in stainless steel and they were always in for repair due to cracking and thats prob why no ones done one in stainless.

Next time you follow one look at the massive gussets they have on the corners and they still crack.

Its not a weight issue as its not a lot heavier and the tube size used would not be a problem.

Thats my thoughts on it anyway