DIY aluminium roof rack? sure why not :D

[paranoid56]

so i was looking at the front runner and some others that are alu, but nobody makes one for a first gen tacoma double cab.

so figured why not make one. Something thats easy to build and bolts together.

parts list

• 5" alu stock 1/4" thick (aprox 10ft long)
• screws
• 80/20 Inc T-Slot 1.5 x .75 Aluminum Extrusion 15 Series 1575 x 42 Long B1-5

After looking at others i went to the metal shop and picked up some 5" 1/4"thick flat bar.

cut it at 4ft and traced the outline of the roof contour on it. This is where it gets fun I cut the alu to get it close to the shape, around 1/8" to the line. next i made up a wood template that was perfect and smooth. bolted the two together and used a flush cut bit on my table router and make two copys on the alu.

if you try this, make sure to wear good eye and hearing protection as its LOUD.

for the cross bars I am using 8020. I only had 2 so waiting for more to show up. have 6 bars coming for 60ish shipped.

seems to look good so far.

next up was making some feet to mount to the truck.
need to find some shorter bolts, but these will work for testing.

and the first problem i ran into. totally forgot about the contour of the roof in that direction.

and here. i think i am going to make some plastic spacers that mimic the roof better.

 

[paranoid56]

once i get the other parts i will finish up

 

[Scott H Murray]

Looking good, interested to see how it turns out.

 

[MLu]

That's pretty nice! I have the same premise for my DIY rack (easy to build and bolts together), but a lot simpler. Just angled aluminium, holes, nuts and bolts. Yours is fancier and sturdier.

 

[paranoid56]

yea i kinda wanted to show people that you can build a good looking light weight roof rack for under 150 bucks and made with basic tools that most already own

 

[Corneilius]

Looks great, I just made one very similar for a sequoia. I cheated and used the CNC though, router was a good idea.

 

[paranoid56]

Looks great, I just made one very similar for a sequoia. I cheated and used the CNC though, router was a good idea.

i almost did that but my cnc table is only 2ftx4ft and at the ends it gets iffy. and this being exactly 4ft long i didnt want to chance it lol

 

[Corneilius]

i almost did that but my cnc table is only 2ftx4ft and at the ends it gets iffy. and this being exactly 4ft long i didnt want to chance it lol

Gotcha, ours is 4x4, but the rack ended up being like 7'. I did it in 3 lapped sections, joints are practically unnoticeable. I know what you mean about cutting 48" on a 48" table, gotta be right on!

 

[paranoid56]

Gotcha, ours is 4x4, but the rack ended up being like 7'. I did it in 3 lapped sections, joints are practically unnoticeable. I know what you mean about cutting 48" on a 48" table, gotta be right on!

do you have a thread on yours or some pics?

 

[paranoid56]

made up the plastic spacers to match the roof to the rack. I wanted plastic to keep the alu off the paint. also easy to work with
I had some HDPE laying around so it worked out perfectly.

close up.

and i totally cheated making these. i was about to make up a jig to run on the table router, but I looked over at the mill and went to town :lol: this piece is totally doable on making it by hand though.

 

[Rezarf <><]

Bravo boss! Looks great and you might have inspired me to make one myself. Can you post up your source for the crossbars?

 

[paranoid56]

Bravo boss! Looks great and you might have inspired me to make one myself. Can you post up your source for the crossbars?

the cross bars are 80/20 aluminium. they have a outlet store on ebay that you can pick them up for half cost then locally.
once finished, i would say i have under 150 bucks in materials.

also, nice to see a fellow FJ40 owner

 

[Rezarf <><]

the cross bars are 80/20 aluminium. they have a outlet store on ebay that you can pick them up for half cost then locally.
once finished, i would say i have under 150 bucks in materials.

also, nice to see a fellow FJ40 owner

Thanks! And long live the 40's!

 

[paranoid56]

so drilled some big ol holes in the roof and put in some riv nuts. also smeared a lot of silicone to help with any water issues.

and installed, i think i am going to move the light bar as it kinda looks funky lol

and another shot, going to make a matching one for the rear.

 

[paranoid56]

finished up the rear one. i might make it a tad thinner though, but will see. also got the arb awning attached to the front one.