DIY: Building Your Own Overland Roof Rack
Embarking on an overlanding adventure often requires some serious gear, and having a reliable roof rack is essential for carrying all the equipment you'll need. Instead of purchasing an expensive pre-made roof rack, why not build your own? In this guide, we'll walk you through the process of creating a sturdy and customizable roof rack using extruded aluminum.
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Materials Needed:
Extruded aluminum from tnutz.com (10-series, 1" x 2").
CAD software (Shapr3d) for design
Miter saw with an aluminum-cutting blade
1/4-20 nuts and bolts. (10-series)
Drop-In T-nut w/ spring ball (highly recommended! You can roll the nuts in without taking apart the rack)
Corner brackets - There’s lots of options on the site. I chose these for extra support.
Loctite for securing bolts
Step 1: Designing the Roof Rack
Start by sketching your roof rack design using Shapr3d or any other CAD software. Consider the dimensions of your vehicle's roof and the type of equipment you plan to carry. The 10-series 2" x 1" extruded aluminum provides a solid foundation for a robust roof rack.
Ensure that your design includes mounting points for accessories like roof boxes, jerry cans, or off-road lights. Take advantage of the versatility of the extruded aluminum to create a modular system that can be easily customized.
Step 2: Cutting the Aluminum
Once you have the extruded aluminum, use a miter saw equipped with an aluminum-cutting blade to make precise cuts according to your CAD design. Follow all safety precautions while cutting, and wear appropriate protective gear.
Take your time to ensure accurate cuts, as precision is crucial for a well-fitted and stable roof rack.
Step 3: Assembling the Roof Rack
Lay out all the cut aluminum pieces according to your design. Begin assembling the rack by connecting the sections using the 1/4-20 nuts and bolts. Use angle brackets to reinforce joints and enhance overall stability.
Apply Loctite to each bolt during assembly to prevent them from coming loose due to vibrations during off-road journeys.
Step 4: Customization and Accessories
With the basic structure assembled, consider additional customization options. Attach T-slot accessories to the extruded aluminum to accommodate specific gear, such as bike mounts, awnings, or equipment racks.
Remember to periodically check and tighten the bolts as part of your regular vehicle maintenance routine.
Building your own extruded aluminum roof rack can be a rewarding and cost-effective project. By utilizing extruded aluminum, designing with CAD software, and assembling with care, you can create a customized roof rack tailored to your overlanding needs. This DIY approach not only saves money but also allows you to take pride in a roof rack that is uniquely yours, ready to tackle any adventure that comes your way.