I spent a couple of weeks deciding what I wanted to use for flooring on my Brownchurch roof rack. I read through all the threads and considered all options. I really wasn't happy with any of the options as they all are a compromise. Some flooring is too heavy, some split/check, some require protective coatings, some are not UV resistant, some last only a few years before they need to be replaced.
Good flooring that lasts for years can be expensive and relatively high maintenance. I wanted low maintenance, low weight, good strength, and low price. I decided to do an experiment with composite flooring that does not require coatings, has moderate strength, does not check, and is supposed to last for many years, and is relatively cheap. In about five years I will know whether I made the right choice.
I went to Home Depot and purchased "Composite Pickets" that are fake red wood. Each picket is only $3.77, and so the twenty four slats required for the roof rack cost $90.48. The price was right for the experiment. I countersunk stainless steel sheet metal screws, and I also ran slats down the sides of the rack to provide additional floor support and to tie things together a bit more.
Here are the results. It will be interesting to see what it looks like in five years. If I break a slat, it will only cost $3.77 to replace.
Overall result getting ready to test drive and blow off all the swarth in the roof gutter.
Eight countersunk screws per slat.
Jerry can holder in the back.
Close up of fake red wood composite slats.
Underside view with side supporting slats.
Underside with supporting slats.
View of composite slats on side of roof rack.
It will be interesting to see how it stands up to rough use. We tested it by having two 200 lb people walk around on top, and one person slept overnight on the roof rack.
I hope it is durable long term. I will make a report in a couple of years.
For those interested, the one year old Brownchurch rack is still for sale at $200 for pick up in Phoenix.