Mud-club
Vehicle & Technical => Discovery => Topic started by: lee celtic on July 06, 2008, 23:02:09
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A Roofrack :dance: :dance:
I have been looking around for ideas regarding the shape and materials for making a roofrack with front and rear lights plus mounts for bits and bobs etc...
I now have the design roughed out and the materials sorted .however on my quest for a good looking roofrack that is easy to build with limited time and money I found a picture of a roofrack with something on the back I don't know the use for ....
Its the vee shaped bit in the middle :-k is it a mount for something or is the to triangulate the rack for stability :-k
come on wizard tell me it's doing my head in... :lol:
(http://www.mud-club.com/galleryimages/1215380833-912-af_1_b.jpg) :dance:
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A decent roof rack will be my next projecct, it will be interesting to see how your turns out...........I want mine split level a little like the old Safety Devices style, thevee shaped bit in your pic - cant imagine it would give much additional bracing - must be for something specific - dingy mast or something?? front to back not straight up with a sail!!
Edit - cant be for a mast.....got me wondering now.........
Paul
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Here;s my home made effort, it has a few extra bits added now though.
(http://i34.photobucket.com/albums/d144/stuntman1982/DSCF0147.jpg)
(http://i34.photobucket.com/albums/d144/stuntman1982/DSCF0145.jpg)
It does look a little twisted in these shots but it was straightened and fiddled with before fitting.
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Nice work there, my own preference would be round tube and curved corners (may be setting myself something I cant achieve!!) but thats not intended as a critisim....well done!
Like the style and shape of it.
Paul
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Yeh I like round tubing but I must say the mating of two short racks to make that one was an inspired idea that set me off :lol:
I am using 20mm electritions conduit and steel mesh ( I blagged a bending jig off a mate ;)) and fancy doing somthing a bit safety divs and a bit special (ie making it up as I go along :lol:)
I have plans to make it as easy as possible using tools everyone should have in the shed or can rent by the hour .
That way when (or if) it works others can have a go . :D I'm hoping to do a rack blog thingy and post it at the end of the build .
Right off to the shed [-o< [-o<
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Was thinking along the same lines myself - (Thats why I am wanting Thule rack feet.....need 4x 953's)although not sure about welding Galvanised conduit - would use steel tube myself - although I guess a certain ammount of conduit could be blagged from skips etc - A "green" recycld rack??.... blog would be a great idea. Oh - and could you start today so I can learn from your mistakes??!! :oops:
Paul
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Have Started :lol: :lol:
First thing I did was build a frame the same size as the roof out of 2x2 in the garage so I don't get wet ;)
second was liberate some non galv conduit from a skip :D :D I will have to buy some but I know a guy whos got a scrap yard looking out for me and putting any he gets to one side :cool:
the only new stuff will be the coppered mesh and some 60 x 6 flat for the legs and a few nuts and bolts ....
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I'm looking forward to seeing the results, I would say if you are going to have lights and accessories on the rack, weld all the bracketry on to hold the wiring etc before you mount the rack, when they are this big they are heavvvvvvyyyyyy!
My next rack will be round tube, I just used square section as it mated with the half rack easily. I'm also going to make channels for the wiring to sit in and make supports for the boarding along the inside edge of the rack.
Rivnuts are really usefull for boarding out the rack, therefore all you do is bolt through the board and into the rack, no need for a spanner on the underside.
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As I'm using conduit I am planning to use glands at a point where the lights are so I can run the wires through the rack and bring them out close to the lights though waterproof seals into flexi pipe and right into the lights :D
at the moment I am trying to decided whether to slope the the legs to the same angles as the pillars or take them straight up :-k
I have however decided to leave the bottom of the rack flat and not shape it to the roof as this will give me a handy gap to store waffle boards under the rack :D
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heres mine and with height issues to at eastnor aswell
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did extend it abit a few weeks ago
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So are we still taking bets on what the "v" thing is ???
Mine is ...
Mounts for giant beedee boppers to make the truck look like a big ant :D
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was gonna be a w for wizard but he forgot the other bit :lol: :lol: :lol:
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I recon it's for a pair of confederate flags, dukes of hazard stylee :dance:
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:roll: oh god finally touches replys already and lee has on just began making it his
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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) ;)
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Photos my dear Watson.....................photos.................
Good luck with it!!
Paul
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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:
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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 (http://www.mud-club.com/galleryimages/1216587191-7838-roof4%20028.JPG) 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.
(http://www.mud-club.com/galleryimages/1216585117-7686-roof4%20014.JPG)(http://www.mud-club.com/galleryimages/1216585905-9851-roof4%20015.JPG)
(http://www.mud-club.com/galleryimages/1216586019-9229-roof4%20013.JPG)
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 ;))(http://www.mud-club.com/galleryimages/1216586106-8831-roof4%20016.JPG) I worked out where the first upright would be on the back of the rack.(http://www.mud-club.com/galleryimages/1216586188-425-roof4%20017.JPG) 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.
(http://www.mud-club.com/galleryimages/1216586677-3519-roof4%20021.JPG)
Using some 3mm plate I cut some tags to hold the rear work lights and welded them in position,
(http://www.mud-club.com/galleryimages/1216586774-8847-roof4%20022.JPG)(http://www.mud-club.com/galleryimages/1216586902-7051-roof4%20020.JPG)
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.
(http://www.mud-club.com/galleryimages/1216587067-8494-roof4%20025.JPG)
I have now run out of tube :(so off to the scrappers tomorrow :D but so far so good :dance:
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I build roof racks for discovery,s they start at £200
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I've priced mine up at £47 plus paint/powder depending on if the finished item fit's through the oven :lol:
For £200 I'd want to drive it not bolt it on ;)
No dis-respect meant I'm just tight :D
I Haven't done much on it this month as I have been pimping my new Hi lift jack ...( second hand and need of a rebuild and paint)
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Lee don't powder the steel rots out from under it
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AKM, do you have a website or any pictures I can take a look at mate?
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Been looking for a roofrack for a while now, think I might have a go at this!
Unless one of you guys who's alredy done it fancy making another :shock:
Jim
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Funding should be better at the end of the month so more will be done then . I know it's not much but I've diverted this months toy money to a hi lift (don't tell the wife) ;)
I have also started doing proper drawings with angles and stuff .
I tend to make stuff by eye then do the drawings so it can be repeated :lol: :lol:
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Well it's moved on a bit :dance:
I have been doing a bit in the evenings and weekends , to be honest I have found that using the frame I made in the garage and doing everything by eye has worked pretty well. I have used two roof bars I had for carting ladders about to set the heights of the cross supports and I am now happy with the height as it was a bit high at the start..
These piccies are of the first full try on, the light bar is just resting in place as I will need to un-wire it to get it off :roll:
so What do you think :D
(http://www.mud-club.com/galleryimages/1223744341-6306-PIC_1794.JPG)(http://www.mud-club.com/galleryimages/1223744553-7445-PIC_1797.JPG)
(http://www.mud-club.com/galleryimages/1223744636-1762-PIC_1792.JPG)(http://www.mud-club.com/galleryimages/1223744092-3590-PIC_1802.JPG)
Now I need to add some more uprights on the top cage and some cross bars for the deck to sit on :dance: before paint :D
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nice start lee un sure on the bare metal finish :-k thinking the black will more in keeping with ur truck
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Looking really good mate, the front leg of the rack looks a little bare somehow, I really like the lines of it aswell.
How about some bracing for the light bar, then mount 4 wipacs to the front of the roof rack and 4 small rectangular lights hanging off the light bar?
You'll be taking orders soon bud
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Awesome!
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The fronts not finished yet I am thinking of somthing a bit like this on the front but a little further back ;)
To stop the lights hitting the bonet..
also loops on the top corners for bush cables (must remember to wear safety glasses ;)) and thinking of a swivel/ search type light right on the drivers side corner.
(http://www.mud-club.com/galleryimages/1223750990-337-SD2.jpg)
sorry I don't know whos pic it is I have collected so many doing research while designing my rack from ebay and other sites but thanks anyway ;)
this was the very first fit and was just to make sure the frame fitted in the gutters , there is still a way to go but not as far as when I started :dance:
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fantastic mate a real credit to you,well done
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It's looking really good mate.
Keep the updates coming!
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nice start lee un sure on the bare metal finish :-k thinking the black will more in keeping with ur truck
:doh: well done lee well worth all ur effect , looking foward to see new lights in postion
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Hi All
Right I am now happy with the skeleton of the rack so I thought I would start fleshing it out starting at the front . I have said earlier that I would like a sort of roll bar to protect the spots (bust too many on low trees)a bit like this but I think it looks a bit bulky..
(http://www.mud-club.com/galleryimages/1223750990-337-SD2.jpg)
I have mocked up what I think looks good and right (it's only taped together at the moment ) this is just to see if it would work . I plan to fix the bush cables to the corners of this "roll bar"
(http://www.mud-club.com/galleryimages/1224796744-9552-PIC_1892.JPG)(http://www.mud-club.com/galleryimages/1224796816-3400-PIC_1893.JPG)
So the question is what do you all think do the shapes /angles work ??
thoughts please :D
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id say yes compared to just the light bar alone
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Well unless I get any more replies telling me it looks rubish this is how the front is going to stay :dance:.
(http://www.mud-club.com/galleryimages/1224796744-9552-PIC_1892.JPG)
I've been in the garage trying different layouts and I keep coming back to this :D
I Have also got another set of spots with grills (ebay 10 quid) so there will be four round lights on the front , Two work lamps on the back and a rectangular lamp on each side above the doors .
I am also thinking of fitting a couple of universal brake lights next to the work lamps on the back to give early warning to people a long way behind...
I am thinking of running one big wire to the rack to earth it then I only need to take live wires to the lamps is this possible?? and will it work??
and the last thing (for now ;)) quick fists for the hi lift are they any good :-k
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Well mate, that does look cracking. Well done, I reckon it'd look a lot better with 4 big Wipacs and their grills on there though :twisted:
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looks a proper job mate, the only comment I would make would be, could you make the mount tabs for the spots a bit longer, so the spots could sit further back and be better protected?
Chris
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nice job on the rack lee :clap:
quick fists would be ok as long as the jack is laying down,they held mine on the roof with out any probs at all :D
as for the earth strap,it would be alot better if it earth on the rack,thats the way i done mine,with a fuse for every pair of lights :wink:
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Ok The Rack has moved on a bit more ... :D
I have finished the fabrication today so the welder can be put away now :dance: Then I found one of the cans of paint I got had a dodgy top so I ran out of paint :doh: most is now undercoated and about a third is blacked . I have stripped the old light bar and used some of the tube on the rack . I will also be using the bulbs for the new lights as one set didn't come with any.
so here are a few more piccies .. and with a bit of luck I can get the paint finished tomorrow . so far I have used 8 lengths of tube @ £3.60 each 2 cans of paint @ £6.50 each . and four new spots and two work lamps total cost £30 .
(http://www.mud-club.com/galleryimages/1226254731-3196-PIC_2143.JPG)(http://www.mud-club.com/galleryimages/1226254457-9131-PIC_2137.JPG)
(http://www.mud-club.com/galleryimages/1226254357-5855-PIC_2134.JPG)(http://www.mud-club.com/galleryimages/1226254281-9640-PIC_2133.JPG)
I am planing to fit boards to the rack when it's finished like these...
Any ideas what thickness/material they are made of anybody??
(http://www.mud-club.com/galleryimages/1226256379-745-gotk2.jpg)
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That looks gr8.
I want a full rack 4 my disco but i dont no how to go about it.
Any info on how the build went and any problems accured and advice would b gr8.
Cheers rob
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I am hoping to do a full how to type thingy at the end all in one post , I have taken more photos and have a list of everything needed including tools and tips .
I have kept to the mandate of building the rack using only basic tools (apart from the pipe bender) and have not bought anything special to do the job .
so far the hacksaw ,grinder , vice , peice of string (yes string :lol: ) ,wirebrush and tape measure have done most of the work....along with the welder and bender of course :D
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The tube you used.....
What was it??
you said you used 8 lengths of tube @ £3.60 (is that all the tube needed?? What lengths did it come in?? Size thickness?? Size?? etc. etc)
How did you mount the rack to the roof??
Cheers rob
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Electritions tubing you know the surface mounted stuff for factories.
3mtr lengths
this ones made from 20mm but the next one will be 25 mm as this is availiable too . :dance:
I bought 8 lenghts but I had two lengths (bits that made up to two) from the skip at work. :dance:
mounting it to the roof now theres a thing ....
I have a couple of ideas but need to finish the thing and get it onto the gutters to see which one will work best .
I will be wraping parts of the base rail with rubber tape ( self amalgamating ) this will stop slipage and stop vibration (it worked great with the old light bar.
then it will either be bolts through the uprights into L brakets or ali angle pop rivited (this is the one I prefer as it will be harder to nick it). :dance:
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Right no what i am looking out for now :lol:
is that the galv stuff???
So you planning another 1 allreally lol (you havent even finished this ont yet lol) :lol:
It really does look good cant w8 to see the full right up (so i can nick your ideas :lol: )
Rob
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yeh when I started it I wanted the tube bigger like the g4 ones but thought it only came in 20mm but after getting half way a mate told me you can get 25mm :roll:
This one will stay on for a while . I want to do the front bumper next ;) and the boot floor :(
then I will make a new rack in the big stuff ...
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Where dig you get your tubing from??
I can only find it in 1 place and it is ova £15 for a 3 mtr length :-o
What type of bender did you use for the job?? any idea how much i could pick 1 up 4??
cheers rob
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Well it's finished :dance: :dance: :dance: :dance:
but not fitted :'( :'( :'(
I ran out of time tonight but it's all done and will be fitted tomorrow :dance: :dance:
here are a few more pics , it's a bit hard to see it all amongst the clutter but it looks cool even if I say so myself :afro:
(http://www.mud-club.com/galleryimages/1226353565-8990-PIC_2155.JPG)(http://www.mud-club.com/galleryimages/1226353646-8658-PIC_2157.JPG)
(http://www.mud-club.com/galleryimages/1226353513-4279-PIC_2152.JPG)(http://www.mud-club.com/galleryimages/1226353341-5653-PIC_2149.JPG)
I have to say I'm made up with it all I need now is some "MUD CLUB SHED DEVICES" stickers :lol: :lol:
Then I can tidy the garage :roll:
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oh in answer to bobtails question .
I got the tube from lockwell lectrics in Bangor and Newe and Eyre in Llandegai £4.90 and £3.60 +vat respectively though I did get trade discount :dance:
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Superb effort mate, very professional looking! :clap:
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That looks gr8 :lol:
Cant w8 to see it fitted.
Just got to find a friendly sparky then lol :lol:
Thinking about it my uncle is m8s with a sparky who only does factory work (see what i can blag) lol :lol: :dance:
Cheers rob
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Cheers Mate ..
Looking forward to seeing it on the truck . My lads going to help me fit it tomorrow should be easy enough we're both over 6 foot so at least we can reach :lol:
Thats the way to do it bobtail nothing better than free ;)
there is a bender you can buy that just a straight bar with a sort of hook on the end looks like a handy bit of kit , the one I've got is about tenth hand but works great...
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This is the bending tool that I was going to use before I got the other one .
it looks very simple and there are loads of guides on line on how to use them...
(http://z.about.com/d/electrical/1/5/h/-/-/-/bender.jpg)
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Last instalment .. :dance:
Well I am a happy bunny :D :D
the Rack went on like a dream and looks the mutts....
Me and my Lad put it on tonight the fixings need to have a few more rivets put in but it's on solid...
heres a few more piccies , sorry but it was dark when I finished so they arn't that clear I'll get more tomorrow .. so here it is Finished and fitted ..
next project is the wiring ;)
I have most of the old stuff from the old light bar :dance:
(http://www.mud-club.com/galleryimages/1226439847-4990-011.JPG)(http://www.mud-club.com/galleryimages/1226439831-4581-010.JPG)
(http://www.mud-club.com/galleryimages/1226439815-6710-009.JPG)(http://www.mud-club.com/galleryimages/1226439782-1266-007.JPG)
(http://www.mud-club.com/galleryimages/1226439799-9863-008.JPG)(http://www.mud-club.com/galleryimages/1226439737-5616-005.JPG)
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Looks the business mate-Excellent build!
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Time to put it in the for sale section and to start the 25mm version ;)
That looks great mate.
Well done that man :clap: :clap: :dance:
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It's not clear on the pictures but I would make sure you have some decent heavy duty bolt on brackets to fix it to the gutters, I've seen one or two roofracks get ripped off by the flimsiest of looking branches.
I wouldn't rely on rivets being up to the job.
Other than that though, for a first attempt from scratch it looks very good.
If anyone else is thinking of making one using conduit I'd recommend getting the black enamel finished conduit tube - it may not be as hard wearing as the galvanised stuff but it should certainly make the welding of joints a lot easier.
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good work m8
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looks brilliant well done!
How much to build another :-'
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How much to build another :-'
how about 2,looks very nice that mate :clap: :clap:
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How much to build another :-'
how about 2,looks very nice that mate :clap: :clap:
make that 3 lol
we could keep you busy for a few months lol
eob
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4...
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i reckon you could make a fortune selling them it looks really smart :clap:
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agreed there's money in them there roof racks! :thumbup:
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Cheers thanks for the comments Guys :D
I'm not sure about making roofracks , It was a one off for myself really and I think if I were to make them they would cost a fortune because I'd have to have the electric heater full all the time IT'S BLOOMING FREEZING in my garage :(
here are a few more pics taken in the light , I think it looks even better :D stands out well against the silver.
as for the rivets I would rather loose the rack than rip the roof off :lol: :lol: :lol: though I am going to pull test a 5mm rivet through 7075 5mm thick into steel tube at work tomorrow :D we have several pull testers that will pull up to 10 tonnes :dance: I will post results just out of interest myself....
(http://www.mud-club.com/galleryimages/1228337081-4180-002.JPG)(http://www.mud-club.com/galleryimages/1228337122-7247-008.JPG)
(http://www.mud-club.com/galleryimages/1228337201-1139-006.JPG)
I am building something else ;) and so far it looks the dogs danglies :D
Anybody want a sneeky peek ?? :lol: :lol:
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YUP :)
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YUP :)
ill 2nd that :lol:
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Well seeing as you asked so nice ;)
Please remember this is my first go at this and this is only the plug for the mould the end product will be made of fibreglass...But I have tried it on the car and it looks :cool:
I've done a lot of reading and watching of vids on youtube and I think I can do it [-o<
(http://www.mud-club.com/galleryimages/1228509615-7804-024.JPG)(http://www.mud-club.com/galleryimages/1228509662-7548-030.JPG)
(http://www.mud-club.com/galleryimages/1228509747-6981-035.JPG)(http://www.mud-club.com/galleryimages/1228347157-9924-060.JPG)
(http://www.mud-club.com/galleryimages/1228509803-8698-041.JPG)(http://www.mud-club.com/galleryimages/1228509954-3918-054.JPG)
Anybody remember the bit in close incounters with the mash potato :lol: :lol: :lol:
now I am sanding and coating and sanding and coating and sanding and coating until it's super smooth as I have read that the finished product is only as good and the plug for the mould... :D
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Lee,
Just going back to the roofrack for a mo, am I right in saying you only used about 30 metres of tube??? You bought 8, 'found' 2 and they were only 3 metre lengths???
Light pod looks great BTW!!!!
Cheers
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brill work on the light pod fella,
ive been looking at these for mine but think i already have 2 many lights :oops: :lol: :lol:
keep up the great wor dude :clap:
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Just going back to the roofrack for a mo, am I right in saying you only used about 30 metres of tube??? You bought 8, 'found' 2 and they were only 3 metre lengths???
Yeh...well ish...
the rack is approx 2.5mts (ish) long and 1.5 (ish) wide plus legs and a few short off cuts and a couple of bits joined so yeh 30 mts. didn't do a cutting plan though just thought it through as I went along getting the most from the tube...and I did estimate that the found bit's was two lengths (it was in a few bits) :lol:
sounds a lot dosn't it :-k :lol:
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You can never have too many lights :lol: :lol: :lol:
The only reason I want to make one is I would rather spend £85 - £185 depending on who you buy one from ,On making the mould and producing my own with the option for spares for the price of the fibre glass...
plus this is the practice for making wide arches.. if I make my own moulds I can make my own spares for them too :dance:
I also fancy doing a centre consol with a descent radio slot :evil: