Once my outline shapes were very close, I sanded it by hand with wet/dry paper at 220, 320, 400, and 600 grit. That extruded aluminum was something I wanted to try, as I see it often in restroom stall wall applications. 80/20 T-slot extruded aluminum (aka - the industrial erector set) is very lightweight and in my opinion very strong. However, in the end i was able to put this rack together for about $700, if i pretend like i didnt buy hardware twice. :). Is the 80/20 stuff that heavy? This helps transfer the load of the rack to the car, and doesn't put all the weight on the bolts, since they are taking a sheer load. These particular cross bars are pretty large, and I do hear them when I don't have the radio on. Real weight: if I ever take it off, I'll try to get a weight. My sub-compact Chevy Bolt was not the ideal vehicle for getting plywood from my local lumber yard. Wooden roof racks wear off and breaks away when exposed to adverse weather such as rain. Saved by Carol-Ann Mulkey. Only 17 left in stock - order soon. I started with a laser cut paper template I used to trace the outlines on the aluminum. I've got access to a 14" bandsaw and I've been trying to learn to resaw sections of tree like this to make live edge slabs like those pictured here. @ylexlot Material Choice Question, looking to do a similar, albeit more simplified rack. Most places in the world that sell ply are standard size sheets of 4'x8' or 1200mm x 2400mm and when tied on properly you dont need the little angle bits on the end of the cross bars. Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. 1 year ago, Thank you for an extremely Clear, thorough, well-articulated Instructable. A plasma, some forms and a metal brake and you could make this for the Tahoe. For your $200 you could have bought an off the shelf, name brand rack that connect directly to the rails on your car in a few minutes. Discover the magic of the internet at Imgur, a community powered entertainment destination. 3.8 out of 5 stars 8. This helped me eyeball if the angle/tilt front to back was good. They are high enough to keep a few sheets of plywood centered, and I can easily run a rope through the triangular shape. You are using an out of date browser. Here is a roof rack i build from a ladder and some roof rails i didn't use. Thanks! Furniture Home Decor Child Bed Homemade Home Decor Home Furnishings Interior Design. 7355 views on Imgur: The magic of the Internet. Looks like it's pretty useful and sturdy. I needed a new rack to support the weight of the roof tent I'm building, so it was time for a stronger rack. To finish up the install I added flat covers to the ends of the cross bars, and a rubber tread strip along each cross bar. In the end, to feel more comfortable than "eyeballing" the angle, I set a laser pointer on the extruded rail, and used a piece of metal shelf support to see where the laser intersected it from a close distance, then move about 20 feet back and measured again. Roof racks dont need to be fancy, just simple and strong. Not all cars have the same roof layout, so this approach certainly won't work for everyone. It's got a complete parts list. The 80:20.pdf file you can download in this step is a cart of all the exact parts I used from 80/20, totaling $182.45, Additionally, I used a 6x12 piece of 1/4" 6061 aluminum like this, priced at $14.25https://www.amazon.com/gp/product/B00ZRZ7TTI. I could potentially make something for you, but can you sketch it on paper and post the image here so I better understand? This is a roof rack that is ALMOST all DIY. Definitely going to move forward with my build now. I didn't realize that 80/20 weighs that much. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. 3.4 out of 5 stars 16. This gave the surfaces a nice smooth and clean look. FREE Shipping. 7211 views on Imgur: The magic of the Internet. - Since you know how you plan to use the roof rack, you can make it infinitely adjustable to your needs. It looks uber light weight. I don't plan to leave the wide bars on regularly. Up until this point I had the typical 5'x5' sheets of Baltic Birch wood ripped to a size I could fit in the back of my car. I like getting 80/20 from McMaster. I suspect this is a lighter than steel would be for the same size though i suspect welds are lighter than the hardware. Uses of Aluminum Extrusion Racks Aluminum extrusion racks have permeated all aspects of our lives and have created a number of conveniences in day-to-day life. Here's the final design I used for my Chevy Bolt as an Adobe Illustrator file. Nov 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. It has to be less than 80 lbs. For industrial framing or something in a shop, no biggie. 89. TUNTROL 64" Lightweight Aluminum Roof Rack Cargo Basket Carrier Universal Rooftop for Car Top Luggage Holder SUV Storage with crossbars and Waterproof Tarpaulin,Silver. Just the rails alone don't make any noise. Also, I don't want to keep using my car like a pickup inside. I'd remove the cross bars if I'm not planning to use them. Otherwise, consider you might want to make some adjustments to the length and width after you measure your vehicle. $103.99 $ 103. I'm not specifically planning to rooftop camp, but mainly because the car's roof doesn't look like it would support that much weight. I should have covered that! Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. Discover the magic of the internet at Imgur, a community powered entertainment destination. Since this comes from multiple 3rd-party rack venders, I'm assuming this is based on the roof limitations. Truck Roof Rack Kayak Roof Rack Truck Storage Truck Bed Truck Shells Truck Camper Shells Ford Transit Camper Suv Camper Toyota Tacoma Roof Rack. Each pair of holes was measured, and they all turned out to be the same distance apart, 120mm between holes. July 2020. You can easily assemble and disassemble the aluminum roof rack to suit the periodic needs unlike the steel roof racks. FREE Shipping. Looks good, what towers are those? Question Almost 3 weeks before I received the order. Made this in my dads home shop. Steel hardware 60+ m8 bolts, washers, and slotted nuts add up a bit. This is again where you will make decisions based on your use intentions. I’m in California, FWIW.Regards,StanDogRescuer@iCloud.com, Answer I even opted for the "lite" cross sections that have less aluminum. The wood gets sawdust in the car, and will scuff the plastic trim if I'm not careful. What do you think it weighs? Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. This was my 3rd project using 80/20 supplies, and I'm really starting to like working with it! It's a simple and cheap way to make a solid roof rack. And, the aluminum will save weight as well. Article by Palma Emmerich. Rola 59043 Atlas Aluminum Rooftop Cargo Basket. DIY Extruded Aluminum Roof Rack. Lift your spirits with funny jokes, trending memes, entertaining gifs, inspiring stories, viral videos, and so much more. I would have guessed 35 pounds on that thing, but I have never handled the 80/20 extrusions. 99. . As it sits now with the Yakima mounts on the Factory Rack Side Rails and cross beams the basket sits entirely to high off the roof line. Only 5 left in stock - order soon. About: The IDEAWORKS Innovation Suite is part of the Library and Academic Technology department at Washington College in Chestertown, MD. A roof rack made out of aluminum is guaranteed to last you a long time! I hope this tutorial was helpful and useful, or at least somewhat inspiring to try something similar with 80/20 parts. Mar 13, 2019 - Discover the magic of the internet at Imgur, a community powered entertainment destination. There are 302 suppliers who sells aluminium roof rack extrusion on Alibaba.com, mainly located in Asia. Oh, I didn't know McMaster sold 80/20! If this is going on the roof of you new car, you'll want it blemish free. And in my experience Autobahn Cops will spot this a mile away and pull you right over especially in Germany. Railroad Rail Lantern / Sign Stand Split With Axe. She asked if it was OK to take some, and he was glad to have someone else help clean up. There are cheaper materials than ext aluminum. Using specs online, the frame members for my rack should weigh in at a little less than 40 lb. Quick question, what was the materials cost for the setup you have shown here (support rails crossbars and tie down points). I have access to a low-end CNC router, but it was going to be about 80 hours of cutting if I tried that. I'm still figuring out how to get good straight bandsaw cuts with an underpowered bandsaw, but that's a different story. Not everyone just wants “Plug & Play”. Extruded aluminum roof racks are more flexible and offers more room for adjustments unlike the steel roof rack. Some people, like myself, take pride in the (journey) of creating, and making something from ‘scratch’. 95. The rack has been great so far, and I don't really have any thoughts for changes if I were to do it again. To bolt them together, you just slide a flat T-nut in the end of the track, and attach with a 1/4 20 bolt. I wanted the redundancy of two bolts into each part of the rack here, and with easy adjustability. Now I’m making a solar panel mount for a sailboat using a combo of 80/20, extruded tube, and custom aluminum joining plates, similar in heft to the ones I made for this roof rack. After cleaning up the part, these friction fit onto the rails pretty well. I could believe ~80 lbs. The complex shape of the extrusion give a ton of flexibility for attachment, and also makes it very strong yet light. . More information... People also love these ideas. The 2nd version then has level mounting points. I used PLAyPHAb filament which seems to be holding up to the UVs good so far. Shipping for me was about $33. In my case, having this new car, and not having had anything “new” in years, I either wanted a store bought new looking rack, or a rack I made new that matched my style.Half the fun was learning to make something with 80/20 parts! 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