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DIY Roof Drop-in Xterra

Discussion in 'Overland Do It Yourself Projects' started by CapeXterra, Apr 19, 2017 at 2:02 PM.

  1. CapeXterra

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    OB 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
    OB Member #:

    3270

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

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    OB 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
    OB Member #:

    4755

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

    CapeXterra Rank III Supporter + Member

    Location:
    Scituate, Massachusetts
    OB 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
    OB Member #:

    4755

    Map
    looks great, may need to do something like that myself
     
    NW David and CapeXterra like this.

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