Vehicle & Technical > Discovery
Roofrack build .FITTED...
lee celtic:
Added to rough plan ,
Tubes for mounting flags :lol: :lol:
I've just been in the garage bending tubes for the rear of the rack looks sort of g4 at the moment but what I have figured out is I will need a lot more tube :(
The two lengths I started out with have gone nowhere :shock: but it is looking good :dance: (so far) ;)
paulnb57:
Photos my dear Watson.....................photos.................
Good luck with it!!
Paul
lee celtic:
Photos will be at the end as I want to do a complete build without replies to put in the tech bit ;)
though I will put a few teasers in here now and again :lol:
It will take a few weeks as I have a holiday coming up :(
I'd rather spend it in the garage but my wife dos'nt understand me :lol:
lee celtic:
Part 1.
Well I’ve set out to build a roof rack for my Disco as I can’t justify the cost of buying one in the style and shape I want (sort of G4 but not roof hugging).
The brief is simple build a rack using tools found in the average garage and reclaimed steel tube, plate and anything else I can get my hands on.
The only thing that could not be found in my garage that I would need is a pipe bender, I found several on ebay for between £30 and £60 that would suit my needs however a mate had one and after a bit of bartering (swapped it for a bike seat cover) I had the tools. I then built a frame out of 2 x 2 pine the same size as the roof so I can work inside in the dry.
To start the rack I have cut a piece of tube to a manageable length and done a couple of test bends just to see what sort of angles were possible these will come in handy later.
I decided to start with what I thought would be the hardest bends, the double bends at the rear of the rack.
Using two pieces of tube the same length to make both sides of the rack at the same time. The first bend was a little under 90 degrees to run under the rear alpine window and up onto the roof the second bend a little over 90 degrees and then across the roof these were done a little by guess work and trying on the car. When doing the bends I used the stop on the bender to make them match and turned the tube in opposite directions to get a mirror image, the two tubes were then fixed to the frame so they overlapped then marked and cut to make them touch end to end. They were then butt welded together with a metal slug inside to strengthen the joint.
Now I have the starting point I decided to trial fit it to the car (looks good :dance:) I marked on the tube using white tape the position of the tube that would run along the roof to the front of the car. Then using one of the test bends (said they’d come in handy ;)) I worked out where the first upright would be on the back of the rack. The edge of the upper frame will be level with the lower frame (white tape)
Remember every thing has to be done twice as there are two sides to the rack.
Using some 3mm plate I cut some tags to hold the rear work lights and welded them in position,
It may seem strange fitting the lamps and things this early in the build but I would rather make sure they fit now unless I finish the thing then have to hack it up again to get the addons to fit.
I have now run out of tube :(so off to the scrappers tomorrow :D but so far so good :dance:
akmroofrack:
I build roof racks for discovery,s they start at £200
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