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DIY Roof Drop-in Xterra

Discussion in 'Overland Do It Yourself Projects' started by CapeXterra, Apr 19, 2017.

  1. CapeXterra

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    Member #:

    2246

    Map
    So I'd been looking at all the options of roof rack baskets out there and decided to build my own. Figured it wouldn't be hard. Looked at other peoples builds and the DepHep and Garvin drop-ins for ideas. So this DIY build I thought I'd share.

    It's a simple design 30"x48" Aluminum basket like the uni-strut's most people are building. Some items I got were free others payed for. All items can be found or substituted for your needs. I work at a lumber yard so some items i got a discount. Angle was a little tougher to locate. Overall price was about 250$ including what the free stuff might cost. I chose to leave it bare to help reflect the heat away from the already black roof.

    Materials used:

    1/4" x 2" x 4' Aluminum Flat Bar 6pcs
    1 3/4" x 8' C-Channel Aluminum 1pcs
    2 1/4" x 8' C-Channel Aluminum 1pcs
    3" x 5" x 1/2" Angle Iron cut to 6 3" pcs
    1/4 x20 x 1" Aluminum Hex Bolts box of 25
    1/4" Aluminum Washers bag of 50
    1/4" Aluminum Lock nuts box of 25
    5/16" x 2" Aluminum Hex Bolts 2 boxes of 10
    5/16" Aluminum Washers bag of 50
    5/16" Aluminum Lock Nuts box of 25
    2" x 3/8" Zinc Vibration Damping Pipe Clamps 6 each
    Rubber roofing 6 1" strips

    The hardware I ordered from McMASTER-CARR.com

    2017-04-17 17.05.41.jpg

    The hardware used and laying out my design. Above:
    End of rack and mounting bracket. Below
    2017-04-18 18.21.22.jpg 2017-04-18 18.21.55.jpg 2017-04-18 19.36.07.jpg

    The crossbars measure 30" and the rest are all 48" long.
    Brackets are mounted 7" from front and back ends. Center is 22" behind the front. As you can see it splits the Xterra logo nicely. Check out my build for other things I've done. Any questions feel free to ask. I'd include the links but still new to this whole thread building.
     
  2. ASNOBODY

    ASNOBODY Benefactor Benefactor Member

    Location:
    Detroit, Michigan
    Member #:

    3270

    Map
    Nice job man!
     
    CapeXterra likes this.
  3. CapeXterra

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    Member #:

    2246

    Map
    Thanks man. Took me a long time planning and figuring how I wanted it built for my use.
     
  4. SupermanSkye

    SupermanSkye Rank II Member

    Location:
    Coquitlam, BC Canada V3B 6V6
    Member #:

    4755

    Map
    Very Nice Job man! Whats the planned use of the rack?
     
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  5. CapeXterra

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    Member #:

    2246

    Map
    Planned use is going to be for camping gear and at some point MaxTrax and extra water/ fuel storage. May expand on it later on
     
    NW David likes this.
  6. SupermanSkye

    SupermanSkye Rank II Member

    Location:
    Coquitlam, BC Canada V3B 6V6
    Member #:

    4755

    Map
    looks great, may need to do something like that myself
     
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  7. AdvNerd

    AdvNerd Rank I Member

    Location:
    Winter Garden, FL
    Map
    This is awesome! I've been trying to figure out how to build a low profile rack without welding. I need a place to toss fuel and Maxtraxs without sacrificing aerodynamics. This gives me some great ideas! Thanks for sharing!
     
    CapeXterra likes this.
  8. Tomo San

    Tomo San Rank 0

    Location:
    New Hampshire
    Map
    This looks great! I've been considering something similar on mine as well, would like to try to keep it a lower profile.

    The vibration dampening clamps are key! Nice find on those!
     
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  9. CapeXterra

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    Member #:

    2246

    Map
    So an update on my rack build. The cross bars should have been 31" as then trimmed down to avoid having to slot them. Also finished the top basket portion with some more c-channel and 2" aluminum angle. I'm very pleased with how it came out and it's super strong.
    [​IMG]


    Sent from my iPhone using OB Talk
     
    Tomo San likes this.
  10. Tomo San

    Tomo San Rank 0

    Location:
    New Hampshire
    Map
    Looks great! Are you planning to powdercoat it or anything?
     
  11. CapeXterra

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    Member #:

    2246

    Map
    No I think I'm going to leave it bare aluminum to reflect/ dissipate the heat away from the cabin.
     
  12. RedSheep

    RedSheep Rank 0

    Location:
    Harpersfield, NY
    Map
    Here is how I made my own recessed Xterra roof rack .. about $50 in parts from Lowes .., and I have a pair of take-down shotgun cases that I keep my Colman stove and camp-kitchen stuff in ..both of which fit side by side and still stay under the factor rack line so as to not get hung up on trees but also have a set pf larger totes that fit up there if I need more room

    Made the rack back around '01 or '02 and it's still on the tuck and working just as well as when I first put it on
     

    Attached Files:

    SupermanSkye and CapeXterra like this.

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