How To: Roof Rack Crossbars on the Cheap ! - JeepForum.com

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post #1 of 68 Old 09-02-2009, 10:54 AM Thread Starter
95BadBoy
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How To: Roof Rack Crossbars on the Cheap !

I'd been thinking about a roof basket for the KJ but needed some decent crossbars, but all the ones around seemed like a lotta dough for what they were & they sat way higher than what I wanted. Then I happened opon a write up buy XC204 on another forum that looked like the answer to the problem.

Needed items

1 10' stick of 1" rigid conduit - (1 3/8 outside diameter) 22.00

4 Chain link fence Clamp on tee's(I used the now discontinued Harbor Frieght ones) Item # 95720 they were 2.99 then marked down to like .87 ea - these may be real hard to find though.

1 can Rustoleum black spray on bedliner - 8.00 at smallmart

1/8" foam pad - found some at the local surplus center - 2.00

Access to a Chop Saw, and find a friend that is a sparky to bend the conduit at the ends 1/2" so you clear your roof line.



Cut the pipe so you have a 38" piece for the back & 41" piece for the front.

Have your 2 pieces bent so that you have only 1/2" bend on each end and draw a line on the pipe with a sharpie so as to stay even on both sides for the bending.

Put the pieces together to test fit and tighten up the "t" to the crossbar - spray them with your bedliner and let it cure out. Put a small piece of the 1/8" foam" under your T's and mount em.





Shows roof clearance



Crossbar clamping location



Finished Installation







Again thanks to original poster (XC204) on another forum for the great cheap idea.


Hope this helps someone save a few bucks.


05 TJ RME 42RLE with some things
05 KJ CRD 545RFE, GDE Eco tune, Franky II, Al's 4.5 A-arms, JK Rubi Moabs, Silent Armors 245-70-17's, Spidertrax Adapters, Rola Basket, Fumoto Valve, Pinch welds pounded - Sold 2015
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post #2 of 68 Old 09-02-2009, 12:03 PM
snowboard49dude
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wow thats is a really cool way to make some cross rails

05 KJ
2.5" daystar pucks upfront/OME HD 2.5" rear coils
31's on black steelies
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post #3 of 68 Old 09-02-2009, 03:00 PM
yellocoyote
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I did the same thing but didn't bend the conduit... still clears the roof too. By approx 1/4" in the back, but makes for a nice low-profile roof rack:



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post #4 of 68 Old 09-02-2009, 03:09 PM Thread Starter
95BadBoy
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yellocoyote

That looks great, which basket did you use. Like everyone does, I did try the bars straight just to see - Was making contact on the back sooo I went ahead and bent em. Don't think it would be any issue for 200+ lbs on top with this little mod.

05 TJ RME 42RLE with some things
05 KJ CRD 545RFE, GDE Eco tune, Franky II, Al's 4.5 A-arms, JK Rubi Moabs, Silent Armors 245-70-17's, Spidertrax Adapters, Rola Basket, Fumoto Valve, Pinch welds pounded - Sold 2015
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post #5 of 68 Old 09-02-2009, 03:49 PM
yellocoyote
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I've got the Black Widow roof rack. It was great for our trip to Ouray, CO/Moab back in July.
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post #6 of 68 Old 09-02-2009, 08:08 PM
DaveJKJ
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Great job and idea to fab up the roof rails.

War Veterans Jeep Group #31
Black Jeep Society #217
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post #7 of 68 Old 09-02-2009, 08:13 PM
jp7794
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Very nice work.
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post #8 of 68 Old 09-03-2009, 07:52 AM
PhotograJeep
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Wow! sooo cool. I will definately try this on my KK. We will see how that works out. Thanks again BadBoy!
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post #9 of 68 Old 09-03-2009, 01:28 PM
Luke09
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Very nice ... cleaner than my version. I like!

2005 Liberty Renegade - Dark Khaki
Frankenlift IIP, Mobil1 Synth.& Filter, PIAA Extreme White, Amsoil EA Filter, Spidertrax 1.25, 245/75/16 Duratracs
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post #10 of 68 Old 09-03-2009, 09:27 PM
babes66
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I've been trying to think of a way to fab some roof rails for my renegade, this looks like it will work like a charm. thanks!!!!
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post #11 of 68 Old 09-06-2009, 11:35 AM
PhotograJeep
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Hello everyone. This is PhotograJeep's wife. He is in the process of fabricating the cross bars for our 2008 KK Liberty at work. He asked me to measure the how far apart the roof rails are from inside corner to inside corner on top, as well as on bottom. I think I just completely suck at measuring, because I'm getting weird measurements. Does anyone know the exact measurements of this so I can let him know? I have searched online, but so far, I haven't had any luck. I'd greatly appreciate it if I could get a response ASAP to my email....geneviag@yahoo.com. Thanks so much.

Photographer and Jeeper, Ken. 08 KK Custom Crossbars.
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post #12 of 68 Old 09-07-2009, 01:33 PM
Liberty6
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95badboy....Great lookin rack.
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post #13 of 68 Old 09-07-2009, 01:57 PM Thread Starter
95BadBoy
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Quote:
Originally Posted by Liberty6 View Post
95badboy....Great lookin rack.

Whoa there big fella, I don't - oh wait , yah the Jeep.

05 TJ RME 42RLE with some things
05 KJ CRD 545RFE, GDE Eco tune, Franky II, Al's 4.5 A-arms, JK Rubi Moabs, Silent Armors 245-70-17's, Spidertrax Adapters, Rola Basket, Fumoto Valve, Pinch welds pounded - Sold 2015
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post #14 of 68 Old 09-07-2009, 02:01 PM Thread Starter
95BadBoy
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Quote:
Originally Posted by PhotograJeep View Post
Hello everyone. This is PhotograJeep's wife. He is in the process of fabricating the cross bars for our 2008 KK Liberty at work. He asked me to measure the how far apart the roof rails are from inside corner to inside corner on top, as well as on bottom. I think I just completely suck at measuring, because I'm getting weird measurements. Does anyone know the exact measurements of this so I can let him know? I have searched online, but so far, I haven't had any luck. I'd greatly appreciate it if I could get a response ASAP to my email....geneviag@yahoo.com. Thanks so much.

Sorry - did not see this yesturday - and I don't have a KK to get measurements from. Maybe someone with a KK will chime in for you.

05 TJ RME 42RLE with some things
05 KJ CRD 545RFE, GDE Eco tune, Franky II, Al's 4.5 A-arms, JK Rubi Moabs, Silent Armors 245-70-17's, Spidertrax Adapters, Rola Basket, Fumoto Valve, Pinch welds pounded - Sold 2015
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post #15 of 68 Old 09-07-2009, 04:21 PM
PhotograJeep
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I hope they do...if not, I'm probably going to have to spend $100 or more on tools so my husband can cut it down tonight when he comes home from work. He has to install them tonight because we are leaving on a trip tomorrow morning, and need to use a roof top carrier.

Photographer and Jeeper, Ken. 08 KK Custom Crossbars.
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