DIY Roof Rack





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Thread: DIY Roof Rack

  1. #1
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    Smile DIY Roof Rack

    Hi Gents

    Plz give ideas/design for a DIY roof rack for Pajero LWB (gen2) i need one for Namibia next year.

    Ruan Seymour

    Pajero 3000 V6 LWB 6g72

  2. #2
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    Hope I'm not hijacking this thread, but I am busy designing a roof rack to go on the cab of my bakkie. Dimensions 1.2m x 1.1m. I have calculated the weight to be 20kg using mild steel. Would this be regarded as a practical weight for such a roof rack?

    I would use it for solar panels (13kg), gas bottle (guess 10kg) and a few odds & ends (5kg) so total weight on the roof incl rack would come in at about 50kg. Is this excessive?
    '06 Isuzu Kb 300 TDi LX 4x4 D/C

  3. #3
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    Quote Originally Posted by PaulG View Post
    Hope I'm not hijacking this thread, but I am busy designing a roof rack to go on the cab of my bakkie. Dimensions 1.2m x 1.1m. I have calculated the weight to be 20kg using mild steel. Would this be regarded as a practical weight for such a roof rack?

    I would use it for solar panels (13kg), gas bottle (guess 10kg) and a few odds & ends (5kg) so total weight on the roof incl rack would come in at about 50kg. Is this excessive?
    How are you attaching the roof rack onto the roof? with rails like from 4x4 direct / frontrunner or are you using roof racks? factory roof bars?

    the roof will handle that weight if properly installed.
    Currently do not own a 4x4, driving a sedan
    Ex: 2013 Ford Ranger 3.2 XLT 4x4 auto
    Ex: 2012 Ford Ranger 3.2 XLT 4x4 auto
    Ex: 2013 Ford Ranger 2.2 XLS 2WD manual
    Ex: 2009 Mazda BT50 3.0 CRDi double cab manual

  4. #4
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    Default

    Do you have roof rails or do you want to bolt the roof rack onto the roof itself? I made one from 25mm aluminium square tubing and connect-it's that clamps onto my roof rails and it is quite strong. Cost about R600 and quick to build.
    '02 Toyota Prado 3.0 td VX, SAC intercooler, Kumho KL78 A/T's. DIY roofrack and rack system.
    "Good judgement come from experience, experience come from bad judgement"

  5. #5
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    Quote Originally Posted by Andz View Post
    How are you attaching the roof rack onto the roof?
    I have a set of Thule load bars on that has a channel used to mount accessories.

    A far as I can tell the weight limit given by Thule is 75kg.
    Attached Images Attached Images  
    '06 Isuzu Kb 300 TDi LX 4x4 D/C

  6. #6
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    Quote Originally Posted by WernerS View Post
    Do you have roof rails or do you want to bolt the roof rack onto the roof itself? I made one from 25mm aluminium square tubing and connect-it's that clamps onto my roof rails and it is quite strong. Cost about R600 and quick to build.
    I have considered 25mm aluminium square tubing and connect-it's, however I couldn't settle on a practical design that I liked given the limited choices in configuring the bars. What dimension is your roof rack and what did it weigh in the end?
    '06 Isuzu Kb 300 TDi LX 4x4 D/C

  7. #7
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    Quote Originally Posted by PaulG View Post
    I have considered 25mm aluminium square tubing and connect-it's, however I couldn't settle on a practical design that I liked given the limited choices in configuring the bars. What dimension is your roof rack and what did it weigh in the end?
    Connect its and alu tube is the easiest and lightest.

    you can also consider aluminium rectangle tube for the slats and u channel mild steel for the outer frame.
    the rectangle tube fits tightly in the u channel and you can bolt or pop rivet it together.similar to the front runner assembly. ( the assembly instructions are available online if you go to frontrunner webpage, select any slimlineII rack and then fitting instructions.
    Currently do not own a 4x4, driving a sedan
    Ex: 2013 Ford Ranger 3.2 XLT 4x4 auto
    Ex: 2012 Ford Ranger 3.2 XLT 4x4 auto
    Ex: 2013 Ford Ranger 2.2 XLS 2WD manual
    Ex: 2009 Mazda BT50 3.0 CRDi double cab manual

  8. #8
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    Default Re: DIY Roof Rack

    Quote Originally Posted by WernerS View Post
    Do you have roof rails or do you want to bolt the roof rack onto the roof itself? I made one from 25mm aluminium square tubing and connect-it's that clamps onto my roof rails and it is quite strong. Cost about R600 and quick to build.
    HI. In the process of building a RR... Do you have any photos of yours?

  9. #9
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    Default Re: DIY Roof Rack

    Quote Originally Posted by cruiser View Post
    HI. In the process of building a RR... Do you have any photos of yours?
    Hi Cruiser

    Would be keen to see how you progress... I am considering building one as well with 25mm Alu Sq tubing, with support struts and Chequer plate for the base. The issue I have is finding functional load bar and brackets to fit into the Cruiser Bakkie roof channels... Any thoughts?

  10. #10
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    Default Re: DIY Roof Rack

    See attachment - built year before last.

    Cost for Frontrunner foot rail set was R1 500 and roofrack was not more that R1 400 IIRC.

    New would have been in excess of R 6 500!!

    Carried 18"2nd spare, gazebo, gasbottle, Howling moon 3x3m ripstop tent etc. for more than 6 500 km in Namibia/Botswana!!

    Benefit is that, if I change vehicle, I can use the RR again, just need new footrails for the specific vehicle.
    Attached Images Attached Images  

  11. #11
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    Default Re: DIY Roof Rack

    Great do you perhaps have a photo?

  12. #12
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    Default Re: DIY Roof Rack

    Quote Originally Posted by waynegrey View Post
    Great do you perhaps have a photo?
    I will have to search/scratch. Currently not on vehicle, but suspended by means of Fredlin hoist. Will see what I can do when home.

  13. #13
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    Default Re: DIY Roof Rack

    It's not a roof rack but it could be.

    https://www.4x4community.co.za/forum...ack?highlight=

    Weighs 30 odd kg.

  14. #14
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    Default Re: DIY Roof Rack

    Hi
    i built mine last year for my December trip.
    It was easy at cost me just under R800 for all the aluminum
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  15. #15
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    Default Re: DIY Roof Rack

    Quote Originally Posted by waynegrey View Post
    Great do you perhaps have a photo?
    Hi Wayne,
    Attached as requested. I had the rails powder coated prior to assembly and then touched up with black paint after assembly (Connect-it connectors, etc).
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