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  1. #1
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    Default It all starts with cardboard (DIY roofrack build)

    I'm rather a DIY fan and so began the journey of building my own roofrack...

    First things first, I needed a way to attach the rack and since I really don't like the generic roof tracks you can buy, I opted for the well designed and vehicle matched Frontrunner tracks. Turns out you can't buy them by themselves, you need to buy a FR rack as well. You can't even see them listed as a separate product on the FR website.

    Off to my friendly FR installer I go, chat to them and since they're an installer, they can buy parts and can see them on the website too. Ordered, paid and the tracks were fitted by the installer (~R1500)
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    Next up was time for the cardboard. Lots of it. Measuring, trimming, all sorts. I never got the roofline perfect, but, well, I'm no enginerd anyway.
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    Off to CAD. That was a bit of a learning curve!
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    Then laser cutting and I had my parts in 2mm 304 stainless. (~R260)

    Next up was the cross bars. For these I ordered 30x60 extruded aluminium "8020" from Modusam. Along with a bunch of T-nuts and bolts. (~R1500)
    My least favourite part of fabrication:
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    All done. Unfortunately I had to settle for cap screws - I was hoping for button heads, but I couldn't find them anywhere in M12 SS.
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    First test assembly
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    Then fitted
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    Last remaining step is to disassemble the whole thing again, send it off for black powder coating and it'll be done.

    (Oh yes, and I've provided some holes at the front so that I can make a future wind deflector if I decide I need to).

    ZS5CMA
    ******
    His: '17 Hilux GD-6 4x4 A/T ~125000km
    Hers: '19 Mitsu Eclipse Cross ~ 25000km
    Semi-retired: '12 Polo BlueMotion ~350000km
    Burned to a crisp: '05 WJ 2.7CRD
    https://www.instagram.com/fstopza/

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  3. #2
    Join Date
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Very nice!!!

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  5. #3
    Join Date
    May 2018
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Great stuff...

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  7. #4
    Join Date
    Sep 2019
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    Pretoria East
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Looks very light. I'm sure it will look good in black.

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  9. #5
    Join Date
    Mar 2018
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    Ellisras
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Very nice! How is the wind noise at highway speeds?

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  11. #6
    Join Date
    Mar 2012
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Quote Originally Posted by WantOnsKan View Post
    Very nice! How is the wind noise at highway speeds?
    I'm not sure yet. I finally fitted it to my bakkie yesterday afternoon, but I'm Covid+ at the moment so I haven't left the house yet. Will probably only hit a highway next Monday and then I'll know what it sounds like.

    ZS5CMA
    ******
    His: '17 Hilux GD-6 4x4 A/T ~125000km
    Hers: '19 Mitsu Eclipse Cross ~ 25000km
    Semi-retired: '12 Polo BlueMotion ~350000km
    Burned to a crisp: '05 WJ 2.7CRD
    https://www.instagram.com/fstopza/

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  13. #7
    Join Date
    Mar 2018
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    Ellisras
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    Thumbs up Re: It all starts with cardboard (DIY roofrack build)

    Would be great to know. Take it easy, get well soon

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  15. #8
    Join Date
    May 2009
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    Ruimsig
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Get well soon Boet

    Rack looks the bizniz
    Estee = S T = Sean Towlson

    Total 4x4 Novice with no experience whats-so-ever

    ''Nothing makes the Earth seem so spacious as to have friends at a distance; they make the latitudes and longitudes''. H.D. Thoreau.

    Hummer H3 V8

    W.A.P Objectivist

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  17. #9
    Join Date
    Jun 2010
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    White River
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    Default Re: It all starts with cardboard (DIY roofrack build)

    Very nice! Love project write ups like these. Please give a total of what everything cost including the powdercoating? Very tempted to try this
    Life's a garden, you just gotto dig it - Joe Dirt
    Sometimes you just gotto keep on keeping on - Joe Dirt
    Life's hard. Its even harder if you're stupid - John Wayne

    2018 VW Amatrok BiTdi 4Motion

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