By Ron on Thursday, March 29, 2001 - 09:38 am: Edit

Ok,
I have decided to undertake another project in the near future. I wish to make a stainless steel roof rack (it will not be for the Disco but it would fit if I gave it longer feet). I have a good design for gutter mounts (happy to share if anyone wants). My questions are:

1. Where would be the best (cheapest) place to buy the raw materials?

2. I have near zero welding experience, none with stainless steel. Is this the type of welding I could try for my first go (with some practice on scrap before hand). What I mean is SS harder to weld than normal steel. Also I want to use SS wire. I plan to weld with a 135 amp hobart MIG I think I am going to buy.

3. What do you exspect would be a fair price for raw materials? Assuming I make it out of 3/4 or 1in square tubing and it is a full length with 6in sides. Basically about 80-90ft of tubing from my guesstimate.

By 94 RRClassic LWB on Thursday, March 29, 2001 - 07:52 pm: Edit

Stainless Steel sounds pretty cool and unique. You might have to do some maintenance to keep it from staining after the rain, but I like it. 80-90 feet sounds right, but also pretty heavy. I say go with the 3/4 just to save weight, because it is steel and not aluminum, it will be strong enough. I was thinking of this myself. I was going to do the same, but I was going to make the floor out of aluminum and then just bolt that in. Since I can't weld aluminum, I was just going to have some shop do the welding for me. I don't think it would be too expensive. The main concern for me is the weight, as I get pretty nervous when I am off camber.

I would love to hear your ideas for gutter mounts. It seems like there are easy ways and hard ways.

I am in the process of welding up a rear bumper for my Range Rover Classic. I am making it in the same style as the Safari Gard concept, but I don't think it will look anything like it. Oh well, I am having tons of fun, and I am saving money at the same time.

Brett Gottdener
94 RRClassic LWB

By Ron on Friday, March 30, 2001 - 03:31 am: Edit

Rear Bumper sounds good. I have lots of stuff planned. But first i want to do the roof rack. For the gutter mounts you flatten the end of the tube, weld it shut and then bend it over to conform to the inside of the gutter. Then you take a piece of flat stock bent ~100degrees and put it underneeth. You then drill though both a little bit off then push down on the rack and slide the bolt though.

Ron

By Rod Burner on Friday, March 30, 2001 - 03:44 am: Edit

Ron;

Stainless is pretty tricky to weld and get penetration. You might want to take a course at your local trade school and pick up some pointers and skill there. Remember always that penetration is what makes a weld safe and strong. MIG is an easy welder to get pretty beads from, but kind of tricky to get good penetration from if you are a beginner. Just telling you this, "cause I am sure that you don't want that rack to come apart on Suicide Gulch or somewhere else, like the interstate. MTCW

By Southern Style on Friday, March 30, 2001 - 03:51 am: Edit

I am working up a design for front and rear bumpers for a DI, made from aluminum diamond plate and steel. It should look good, not be too heavy and would be similar to a cross between $G & Terrain Master. I am thinking of incorporating a steel box in the front one, to mount a winch in. These bumpers would be lighter than ones on the market and most likely as strong. I will keep y'all informed as to the progress and try to post some pictures as it progresses.

By Ron on Friday, March 30, 2001 - 05:20 am: Edit

Rod burner,

Thanks for the input. I was going to use the BFH test on it and I never put heavy stuff up there. I guess I will just buy some scrap and practice and see how I do. I would love to take a course but my schedule just doesn't jive with whats offered. I have read like three manuals and a ton of stuff on the internet and so I think I am going to try. I will let all know how it comes out. First I have to go pick up the truck I am going to put it on. Another rover, woo hoo. I can't wait!!!

Ron

By Rod Burner on Friday, March 30, 2001 - 07:05 am: Edit

Ron;

Cool, another Rover; you have the sickness pretty bad eh? Just take your time with welding and practice first. If you have a book with pictures, look at how they show how the arc is suppossed to look, and try to keep yours within that range.

By Ron on Friday, March 30, 2001 - 07:17 am: Edit

Thanks again.
I have the sickness pretty bad but this is the last one until I get rid of another one. It is going to be my "driver" so I can't make it too extreme, nor can I sink serious duckets into it. Therefore I am planning on making the rack rather than buying one as a similar one from Rover$North is like 1500. I want the rack for some extra storage and so I can carry bulky things relatively easily, like the trop top for the 88 I have to pick up in Maine. I will do my best to figure out the whole welding process and hopefully it will come out ok.

Ron

Co-pilot of the disco
1959 SII 88
1964/110 Hybrid
1988 RR on the way
and some other misc rovers in parts

By John on Friday, March 30, 2001 - 11:59 am: Edit

Poor Ron.

It's like trying to satisfy many women at the same time.

Ron, sell all those POS leaky things and get your own Discovery.

Aren't you tired of being just a co-pilot?

By Ron on Monday, April 02, 2001 - 04:25 am: Edit

I just bought a RR so that is my driver now. Discos are a bit too small as far as front leg room for me to drive comfortable long distances. RR and disco is basically the same truck just a different body.

Cheers
Ron

PS, ironically the disco is the one that leaks the most.

By Alyssa on Tuesday, April 03, 2001 - 06:50 am: Edit

Ron,
Lucas does not leak the most! You know that Noa is the big leaker in the family. Noa's leaked so much she's empty! ...and the new Rangie's PS leak is darn impressive!
Alyssa