Roof rack build - JeepForum.com
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post #1 of 9 Old 12-31-2019, 06:04 PM Thread Starter
jamief
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Roof rack build

I wanted a GOBI but dear god the price on them is way too much for me to justify. So I've been playing in the garage during my christmas break. I've gotten far enough along I figured I'd share.

The tubing is 3/4" EMT. When the weather improves (it's pouring) I'll take a look at my existing roof rails and decide if I want to bolt the frame to them somehow or pull the entire rail and build my own using the 1"x 1.5" box that the frame is currently sitting on.

After that is sorted out I have some 2" mesh to put down on the base and the 2x4's will be replaced with more 3/4" for uprights. I might bring the top hoop down 1/2" or so compared to the 2x4 height.

I also need to remember to add light tabs for a couple of small pods in the back.

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post #2 of 9 Old 12-31-2019, 11:46 PM
2005JGC
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Looking good!

2005 Jeep Grand Cherokee - Work in progress...
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post #3 of 9 Old 01-03-2020, 07:28 AM
badgerwithhands
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My only concern would be what could it handle weight wise. When we get that large, we tend to push the limits with larger items. "Eh, it'll be fine" we say.

FWIW, I built all new rails just like the RRO ones, just 1.5" tubing. My rack, currently still floorless, is 1" steel tubing. Probably stronger than necessary, but the tubing was free

07 WK Overland CRD, cargo LEDs, OME HD, MOPAR skids, rack,
future mods: tires, lights, CB, skids,
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post #4 of 9 Old 01-03-2020, 10:52 AM Thread Starter
jamief
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It's a valid concern. The weight limit will still be determined by the mounts into the roof which are stock and not the most robust. The rack itself won't be the weak link.

Most of what I'm wanting to put up there is quite light. The rack is needed for day trips as the jeep is full with 4 of us and 2 big dogs so things like camp chairs, a sun shelter, bag of extra clothes,... The heaviest thing will be the cooler. For any longer outings I'll be either towing the RV or it will just be two of us and the back seats down will give me tons of space inside.

I picked the rack size based on wanting light bar at the front and pods at the very back and the look. Not so much the capacity.
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post #5 of 9 Old 01-04-2020, 08:42 PM Thread Starter
jamief
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getting close. I've only tacked the uprights in between the base and the top hoop. I'll need to weld that in, clean everything up and then another test fit. I'll be attaching it to the existing roof rails asI noticed on todays test fit that it fits perfectly on top if I remove the cross bars.
I did notice that the sunroof will open fine but vent barely touches the rack so I will figure out how big of a spacer I'd need to add at the front to get it to clear. Hopefully it's under 1/4".
I'm thinking about adding a couple of front feet on the rack as I think the overhang looks strange.
When all that's done it's time to clean and paint. Weather isn't looking warm enough to do that any time soon though which is ok as my christmas vacation is almost over so it may be awhile before it's finished and mounted.
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post #6 of 9 Old 02-03-2020, 12:17 AM Thread Starter
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Cold weather forced me to wait to paint but I got close to finished this weekend when the pineapple express came through and warmed everything up. Sadly were' back down to freezing so it'll be a few more days before I can finish the little touch ups needed. After that It'll really need to cure before I can mount it. It's just Rattle can Rustoleum bedliner
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post #7 of 9 Old 02-03-2020, 06:55 AM
KUJeeper82
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You may want to consider upgrading your roof mounting hardware, the OEM rivnuts are super cheesy.

These are the ones I used for my roof rack. You can pop out the factory rivnuts pretty easily with a prybar.
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post #8 of 9 Old 02-03-2020, 02:56 PM Thread Starter
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Do you need access to the inside to install them?
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post #9 of 9 Old 02-03-2020, 03:39 PM
KUJeeper82
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Quote:
Originally Posted by jamief View Post
Do you need access to the inside to install them?
Blind install. Need to remove the factory ones first (prybar), then use epoxy to seal the hole before inserting. I went one step further and used 3M sealant tape. Rock solid now. $36 for a pack of 10 off amazon...

Here's a link to them and the 3M tape:

Weather Guard WEATHERGUARD... https://www.amazon.com/dp/B00EAANKGC...p_mob_ap_share

3m 1" (25mm) X 9 Ft VHB Double... https://www.amazon.com/dp/B00MAT2WZU...p_mob_ap_share
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