I want to make a custom roof rack.

So I have access to some nice tools in my shop. Mechanical Tube bender being one of them. Used mainly for electric wires throughout an aircraft. I'm pretty sure it will let me bend aluminum tubing up to 1.5" in diameter and steel up to 1".

My FJ is pretty much the only one without a roof rack. And I feel that its time. I pretty much want to make a replica of the gobi stealth roof rack. I feel like it's perfect for what I want to carry. (snowboards, kayak, spare tire, roof rack lights). And I love the low profile of it. Theres only a couple issues I need to figure out...

-Angles to bend, to allow the roof rack to go with the contour of the roof.
-Price of the tubing I will need. (I'd love to be able to use the shops supply of tubing, but I'm sure the gov't wouldn't like me using tax payers money for personal projects.)
-Welding the tube/pipe. I have no welding skills what so ever. poop I dont even have a welder, but I'm sure I can find someone.

I have access to a paint booth and my own gun, so painting it shouldn't be a problem.

Anyways, anyone ever taken on a project like this? Any advice or suggestions. I'm going in blind.

Seems pretty involved, but definitely can be done!

http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/112445-home-made-roof-rack.html

http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/109892-finished-roof-rack-pictures.html

http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/153139-roof-rack-mount-spacer-build-2.html

Mike (BigDogDewey) built his roof rack I believe. he will probably chime in here with some advice/help.

Thank you gentlemen. Btw I'll be back in north carolina next thursday till Saturday afternoon if any of yous want to meet up... and maybe talk roof racks lol.

Edit: Thought I read Sunday instead of Saturday.

Yeah, Gotta be back at work on sunday. But Columbia isnt that far from Charleston from what I hear.

Anyways, I like this guys idea the most.
http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/112445-home-made-roof-rack.html

Looks like I'll go with .85 steel. Going to take some measurements today. I'll have to see how much I will need.

Found another

http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/69495-welded-up-my-own-roof-rack-pics.html

FonnieJr wrote:

Yeah, Gotta be back at work on sunday. But Columbia isnt that far from Charleston from what I hear.

Anyways, I like this guys idea the most.
http://www.fjcruiserforums.com/forums/interior-exterior-visual-tech/112445-home-made-roof-rack.html

Looks like I'll go with .85 steel. Going to take some measurements today. I'll have to see how much I will need.

I really like the idea mentioned in that thread about using the PolyMax poultry flooring as the basket floor. Seems durable, rot/rust-proof, and fairly inexpensive. http://www.farmtek.com/farm/supplies/prod1;ft_poultry_equipment-ft_poultry_fencing_flooring;pgha2215.html

Would be cool pending it doesnt whistle or sound like a kazoo or something on the freeway!

that would be either hilarious or horrible lol.

I figure I need about 45 feet for what I want to do. Not exact measurements, just an estimate to be safe. I can make the 6 metal brackets in my shop no problem.

Now to find someone who can weld.

i used 1 1/2" O.D. .085 wall tubing for the main lower structure...and 1" O.D. .063 wall tubing for the top rail and light cage...and 1/2" square tubing for the flooring run the length of the roof...the rear mounts are narrower than the front and the middle mounts are just about between them ...i can stand on the 1/2" flooring with no problem and on the top rails and bounce up and down...(just ask Speedrye)..if hit a couple of thicker branches at URE with no issues. bought 2 sticks (21' each) of the 1 1/2" and 3 sticks of the 1" and over bought 1/2" square tubing...bought like 5 sticks and used 3 i think? anyway was a fun but lengthy project...changed things around a few times and wasted tubing just to see what would look good or not...

Also check with Cliff. He built his roof rack (flat style) and this weekend I'm going to go hang out while he's working on his rear bumper. I would definitely talk to him.