Simple D2 roof rack

[eburrows]

Hi all,
For those contemplating building vs. buying a roof rack, here is my option: A relatively simple rack made of tubular steel, designed for minimum height, ease of fabrication and strength.

Build log is on my web site:
http://www.erikburrows.com/?node=Custom+Discovery+Roof+Rack

It's made of 1.26OD chromoly steel tube which is compatible with Yakima toy mounts, has only two bends (at the corners), is more than strong enough to stand on and transport gear, and wieighs only about 30 pounds. It's not fancy, but it is simple and sturdy.

FYI: The big hole in the front is to fit a solar panel. Haven't gotten to that yet.

 

[Rover_Hokie]

I like the rack, but disagree with your politics! Rover on!

 

[helievacpilot]

I like the rack, but disagree with your politics! Rover on!

Did I miss the politics?

 

[hilltoppersx]

Did I miss the politics?

i think he means he rather carry coal in his truck then use a roof mounted solar panel.

 

[pinkytoe69]

I found no politics either.

This, however, was an intriguing "would I?"...

 

[Corprin]

i think he means he rather carry coal in his truck then use a roof mounted solar panel.

It's "clean coal" thus his argument is sound!
:banghead:


I like the flat nature of the rack, I need to figure a way of getting my RTT onto my SD rack, in some ways I wish it was missing the side rails... $400, I am not wishing too hard.

 

[eburrows]

Here's a picture to demonstrate the rack's strength (and non-fall-off-truck-ness), I'm about 240 lbs, and it barely flexes:

 

[Rover_Hokie]

Did I miss the politics?

An article in his list of articles down the left side of his web page.

President Barack Obama!

"Barack Obama isn't perfect (see FISA), but he is the finest person to run to be president of the United States in my lifetime. He will be president, and with our help (and guidance!!!) he will be one of the very best this country has ever had. He will undo much of what has been broken, and put us back on the path set by the founders of the United States of America."

Is the politics I was referring to that I have a differing view on.

 

[p m]

Erik - looks good. I'd buy one (although, I'd like to see some gussets).

 

[Disco-very]

I found no politics either.

This, however, was an intriguing "would I?"...

Pass on the oral and you will be okay.

 

[DownUnder]

Pass on the oral and you will be okay.

I will just pass altogether thank you:ack:

 

[Nomar]

Here's a picture to demonstrate the rack's strength (and non-fall-off-truck-ness), I'm about 240 lbs, and it barely flexes:

Not bad.
I'm guessing no sunroofs?

Still, I think it would look a little better if it dropped in the front to match Discovery's roofline.

 

[eburrows]

PM: Agreed gussets would increase strength, and be easy to add. My testing of weld strength showed it was not necessary for the loads I expect to carry. However, if I was going to put > 100lbs up there regularly, I would add them.

Nomar: No sunroofs, and I even removed the factory roof rails. I wanted to get it as low as possible. Even with my 2" lift and rack, I fit in most parking garages, which is very nice. It is actually angled down in the front about 1cm. I experimented with different angles, and this was the least obtrusive to my eye.

 

[pinkytoe69]

I will just pass altogether thank you:ack:

But the mammaries...they look so succulent

 

[p m]

Nomar: No sunroofs, and I even removed the factory roof rails. I wanted to get it as low as possible. Even with my 2" lift and rack, I fit in most parking garages, which is very nice. It is actually angled down in the front about 1cm. I experimented with different angles, and this was the least obtrusive to my eye.

This is almost exactly what I wanted to do!
You don't have to remove factory roof rails, if you build the floor in such a way that the factory rails fit between the floor bars.
The rack can be easily fitted with flip-up or mountable side/front/rear vertical walls - which can be stored separately, and used when necessary. Full roof-length flat floor makes for a great sleeping place (when bears are considered).

 

[eburrows]

This is almost exactly what I wanted to do!
You don't have to remove factory roof rails, if you build the floor in such a way that the factory rails fit between the floor bars.

This was my first thought too. The difficulty is that I wanted to put cross-bars at each of the body pillars, and run them as close as possible to the roof, to keep height down. This puts the factory rails right in the way. You could still do it if you either raised the floor of the rack above the factory rails, or skip the c-pillar cross-bar.

 

[p m]

I'd skip the C-pillar bar - for the reason that if there was a load near the factory rails, they could take quite a bit of it.