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Unread 07-07-2013, 06:57 PM   #1
dnuccio
Registered User
1995 ZJ 
 
Join Date: Jul 2012
Location: Phoenix, AZ
Posts: 3,480
Roof Rack Mount: Write Up

I built this rack to haul gear for camping. i originally mounted it to the factory roof rack cross bars, but after thinking about it, I knew there had to be a better, stronger way. So i came up with this.
I started with some leftover 3/4" 16 ga tube from the roof rack build. I measured the distance between the 2 roof rails on the jeep (the lengthwise ones) and cut 2 pieces of tube 38 1/8" long.


next, i made 4 small plates 3/4" square. i drilled a 5/16" hole in the middle of each one. then i welded on a 5/16-18 nut on one side of each plate. i took these plates and welded them onto the ends of the tubes i cut. this gives us 2 tubes with threads in either end. i painted them flat black.

next i unbolted the roof rails from the ZJ and drilled holes thru it. the position of the holes will depend on your rack design. i drilled even with the mounting hole 3rd from the front, and the rearmost ones. bolted the rails back to the roof and lined up my tubes with the holes i drilled. i used 2 inch long bolts (probably couldve gotten away with 1.5" bolts though) and bolted the tubes to the rails.




the roof isnt perfectly flat, so you will have to push down on the tube to get it to line up.

now you can either do what i did and use a bunch of hose clamps to hold the rack on, or you can bolt the rack to the cross tubes. i will probably bolt mine in at some point, but for now the clamps are fine. its very strong, i can grab the rack and rock the whole jeep by it.


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Unread 07-08-2013, 02:21 AM   #2
ErikTheRad
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1993 ZJ 
 
Join Date: May 2010
Location: Marysville
Posts: 420
Not bad, but I'd definately use bolts instead of the hose clamps. It probably works ok with the hose clamps but dude, you gotta admit......thats redneck engineering.

Guess I better get busy with pics and a write-up on my new rack. My mounting idea is considerably different than what you've done. I'm gonna mount it on the Jeep tomorrow so we'll see how it works out.
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Unread 07-08-2013, 11:35 AM   #3
dnuccio
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1995 ZJ 
 
Join Date: Jul 2012
Location: Phoenix, AZ
Posts: 3,480
Quote:
Originally Posted by ErikTheRad View Post
Not bad, but I'd definately use bolts instead of the hose clamps. It probably works ok with the hose clamps but dude, you gotta admit......thats redneck engineering.

Guess I better get busy with pics and a write-up on my new rack. My mounting idea is considerably different than what you've done. I'm gonna mount it on the Jeep tomorrow so we'll see how it works out.
yeah in hindsight i wish i had just bought the bolts in the first place and not wasted the 10 bucks on all the hose clamps i bought bolts this morning, will work on it later today when it cools off a bit
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