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Go Back JeepForum.com > Models > Jeep Grand Cherokee & Commander Forums > WK Grand Cherokee & XK Commander Forum > Time for a new Rack

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Unread 06-02-2012, 05:45 AM   #1
Valpacer
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Time for a new Rack

No, i didnt send the missus to Dr Oz with a wad of cash, I started fabbing up a new low profile roof rack for the WH.

Removed the XL vortex, as it made the Jeep look even higher. This new one will be a single layer, but allow me to mount the light bar back on the roof (Yay says AJ!)

Started with some 25mm round, and then some 50x25mm for the cross bars where the mounts will be. The mounts will be similar to the gobi style (thanks for the pics of those Omelet!)

Overall size will be 1600x1200mm. Bent up into two sections, and then used some 20mm as joiner inside the tubes.





All welded up and ground smooth.



Notched the front crossbar mount, ready for welding.







And thats where I ran out of time. Going to have some more 25mm tube cross bars in between the rectangles.

Dave

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Unread 06-02-2012, 05:59 AM   #2
JeepN4KC
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Thanks for the thread, Dave! I haven't seen a roof rack build on here yet - keep the pics walk through comin I'll def stay tuned.
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Unread 06-02-2012, 06:09 AM   #3
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Wont be flash, and using rudimentary tooling, but she will do the job!

The aim is to make it sit at the same height as the factory side rails.

Had to dredge up the old memories from apprentice days to bend the tube, using a hand bender. Wont say how many wrong bits are now in the scrap pile......
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Unread 06-08-2012, 02:15 AM   #4
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Heres the top of the line pipe bender..... havent used one since early apprenticeship days, but it all came back. Sort of



Got the other cross bar in



And the two bars set in place



Got some extra 25mm round cross bars in



And all welded up ready for grinding.



These are the pieces which will become the brackets to the roof.



Slow progress, but its getting there!
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Unread 06-08-2012, 04:14 AM   #5
Budasac
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Lookin' good! I love seeing people fab they're own stuff. Keep it up.
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Unread 06-08-2012, 08:23 AM   #6
Rob 99TJ
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Quote:
Originally Posted by Valpacer View Post
No, i didnt send the missus to Dr Oz with a wad of cash
DAMN!!! I want my click back.




The roof rack looks like it's coming along beautifully.
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Unread 06-08-2012, 09:55 AM   #7
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It's coming along well, man! Nice.
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Unread 06-08-2012, 11:26 AM   #8
S1L3NT_WH33L3R
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I have a design in mind but I dont have the tools :-(
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Unread 06-08-2012, 12:08 PM   #9
Omelet
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Looking great Dave! When you finish I will take an aluminum one, thanks!
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Unread 06-08-2012, 12:09 PM   #10
S1L3NT_WH33L3R
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Quote:
Originally Posted by Omelet
Looking great Dave! When you finish I will take an aluminum one, thanks!
I'll take your gobi!!!
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Unread 06-08-2012, 03:17 PM   #11
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great work dude, looks real nice, cant wait to see it installed!!
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Unread 06-08-2012, 08:49 PM   #12
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FYI the front air dams on the racks make a big difference on fuel mileage.
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Unread 06-08-2012, 09:35 PM   #13
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Quote:
Originally Posted by TangoTango View Post
FYI the front air dams on the racks make a big difference on fuel mileage.
And wind noise!

This is only going to be a single level, no top bars. And 90% of its time is in low range offroad, where aero is not an issue. The other 10% is getting offroad
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Unread 06-08-2012, 09:40 PM   #14
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Quote:
Originally Posted by Omelet View Post
Looking great Dave! When you finish I will take an aluminum one, thanks!
I wish i had a TIG!, in ally it would be awesome. And well to be honest, my Mig welding is good at giving practice with the grinder........

The only bits left to go on the rack itself are the light mounts and some smaller diameter and gauge tubing for the cables to run in. Or i might even run another cross bar for that, i may have forgotten to leave some holes before welding up the tubes to run cables
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Unread 09-25-2012, 11:23 PM   #15
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Bump:

How is this coming? Complete? Pics???
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