Roof Rack build

[zukrider]

since my expo zuk got totalled, along with the rack i built for it, i am going to build a rack for my SR.

this is in the ideas/prep stage. and i have a few questions. for those of you with racks, are you attached to the actory rails? or replacing the rails to use the roof mounts, which i assume are studs? either way, what are your opinions on its strength/stability/overall functionality?

i will most likely build it from 3/4" or 1" EMT again, with crossbars on 5" centers. my zuk rack was all 3/4" with 5" centers and it held my 265# on one bar with minimal bowing. mounting to othe roof is the biggest question as of yet.

its full time function will be lights, hilift, shovel/axe mount, and sleeping platform storage. the platform will be a plywood base @52x88". it will be 2 pieces, together with a piano hinge. it will go on the rack hinge down, and tie in with barrel bolts so as to be quick/cheap/easy. i didnt get to the platform portion with the zuk, but im convinced this system will keep it on and prevent movement, even in wind(crossing fingers). when not in use, it will fold up, and store under the rack, full time. easy deployment. it is based on an REI half dome 2 backpacking tent. i plan to also get a good 4 season 3 person tent in the future, and will build a platform for it accordingly.



please chime in with any info and suggestions you have, and thanx for looking. ill start getting measurements and drawings. pics as they come available.

joe

[zukrider]

here is the zuk rack being built




an overall.


its currently in the trash

[LaOutbackTrail]

Gutter mounts for sure.

These guys have excellent service. They expedited my mounts so that I could mount the rack the day before a trip.
http://www.diamondrax.com/

DO NOT mount to the flimsy plastic existing rack.

[RogerH]

Gutter mounts.

[off-roader]

The OE rack is aluminum, not plastic.

That said, I'd use the gutter mounts. The OE mount location is probably only designed for very light loads.

[LaOutbackTrail]

Mine is ALL plastic. I know this because I cut it into tiny pieces to put it in the trash can..........................

[off-roader]

Mine is ALL plastic. I know this because I cut it into tiny pieces to put it in the trash can..........................

That's wierd. Was it possibly one installed by the dealer? The ones I've seen both on my rig on others have been aluminum. I know because the black paint had faded and the aluminum was showing through from underneath.

[LaOutbackTrail]

That's wierd. Was it possibly one installed by the dealer? The ones I've seen both on my rig on others have been aluminum. I know because the black paint had faded and the aluminum was showing through from underneath.

Not Sure, Ray...

It wasn't exactly plastic, maybe fiberglass reinforced plastic or something, because it had little fibers in it.

[zukrider]

interesting on your rack LA, mine is aluminum. ill look into the gutter mounts. i want to build them though. do you have any detailed pics of the mounts? both on and off?

thanx

[zukrider]

hey RogerH, do you have any info on your monty? maybe we could meet up sometime! if your interested, i am hosting a holy cross trip weekend of aug 19th, your welcome to come!