Ok well me and my friend have matching black XJ's and we were talking a while ago about how he wanted a basket style roof rack, and i said well i probly could make one of those pretty easily in my shop class. Well by Monday i had metal and started fabbing up a roof rack. I'm only 16 years old and i'm in my 3rd year of shop class so i have basic fab skills and access to any tool I would need for this project.
Started off with plans and a rendering of what it would eventually look like.
And then i picked up some 3/4" .065 wall square tubing from a local metal shop.
And then got it to school... 20ft metal bars on a jeep looks pretty funny.
Started getting the cross braces cut and measured up.
Got the edges cleaned up really good for a clean welding surface
And then used the rest of that 20ft piece for the upright supports.
Then cut 20 degree angles for a corner piece so the rack didnt just look like a box.
And then the frame mocked up.
All ready to tack in place.
A decent weld..
And then i got the corners cleaned up nicely with a grinder and then with a flap wheel.
And a little test fit.
And then one of my tack weld's was about 1/16" off and i went to break the tack off and this happend...
Dosent look that bad but it was bleeding everywhere and i had to get a tetnus shot.
And another pic of the corners.
Then i just welded another fame piece in the exact same shape as the bottom one and got it tacked in place.
So thats my progress up to today (3/16/11) and everything is in place, all thats left to do is finish welding, grinding, and shining it up and getting ready for paint and eventually diamond plate around the corners. Should have it done by this weekend so let me know what you think!