Roof Rack Build w/ Pics

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Every good beach runner needs a roof rack, so I have started fabbing one up.  Here are a few pics of the start of the project:Custom bent and dimpled corner pieces:Custom bent and dimpled side brackets:I was able to get a few more pieces welded in today.More to come...Cheers,tpwww.tompenningtonphoto.com
Reply:I fabbed up some support brackets.  These will help the rack support the weight and abuse of a solid Baja trip with no problem.  I built the supports with a good bit of adjustment in them so the rack can easily be moved and mounted on several types of trucks (FJ40, 60, 80, 4Runner, ect):After hours of welding and grinding, I was finally ready to cut the floor and weld it in:Welding the floor:The expanded metal floors are strong, but they require TONS of welding to keep them from rattling all the time.  This floor is welded in over 200 spots.  It will not rattle...The front and rear support brackets were designed with two adjustment slots in them too:Still more to come...Cheers,tpwww.tompenningtonphoto.com
Reply:Looks good just needs some paint.
Reply:Nice. Did you ever do one in powder coated aluminum? That would be light and indestructable.
Reply:Nice looks good.Can we see a pics of the Truck??
Reply:Looks Good !! What's that sucker weigh ??Anything worth doing is worth doing RIGHT
Reply:This one tips the scales @ +/- 75 lbs.  without the lights on it.  It is a little heavier than I would have liked for the size of the 4Runner.Because of the excessive weight, I am working on a 2nd version now.  I ordered the correct dies for my Hossfeld bender, so the corners will be a smooth bend with the tubing rather than the formed plates.Eventually I will build an aluminum rack, but I am still socking away the $$$$ for a new Tig machine.Cheers,tpwww.tompenningtonphoto.com
Reply:Looks very cool, Can't wait to see it painted and the lights on.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:I think if marketed properly and a distributor is picked up in the 4x4 world, you could have a hot-selling product, especially if you make different variations that will be a "direct bolt on" for each common year/make/model vehicle.
Reply:I had a customer come in a while back that wanted a rack for his 4runner.  He told me that didn't make them, so I made him a custom aluminum one that bolted into the exsisting holes for holding down the rubber strips on the roof.  It was a little tricky because they came in at angles do to the curve of the roof line.  I also had to roll a piece of 1x1 square tube to match the slight curve.  I think the job took me about 3 hours.  But it made me wonder why they don't mass-produce roof racks for the 4 runners, unless each of them are a little different. The I toyed with the idea of selling them, but it passed because that is such a specific item.  A universal one that you have would work out much better.  The only downside would be that you have to drill new holes in their roofs.    Common sense in an uncommon degree is what the world calls wisdom.
Reply:i looked at building a safari rack for my 87 4runner, but decided to buy a truck instead.  you rack looks real good.  i like the punched supports.
Reply:The correct dies for the Hossfeld bender finally showed up and I put them to use.The goal of the 2nd version of this rack is to build a rack that looks good, works even better, and still remains fairly light weight for the 4Runner.I ordered some thiner wall tubing for this rack.  The .083 wall thickness tubing on the first version is super strong, but it ended up being a little heavy for a small truck.  This design also uses bent corners rather than the formed plates.This rack uses a mix of .065 wall thickness and .083 in high stress areas.The rack will hold four lights up front, two wide beam and two pencil beam.Another view.  I was just mocking up a few things to check the design lines before I stared cutting up more metal.More to come...Cheers,tpwww.tompenningtonphoto.com
Reply:More progress pics:I started out welding in the side and rear support posts and plates:Custom "branded" side plates.  The plates are framed with 1/2" square tube:Like the first version of the rack, the mounting plates are notched to offer a flexible fit to several different vehicles.The light mounting tabs were sheared, punched, and welded in:Test fit:I am using two pencil beam lights and two driving beam lights on the rack:I was also able to test fit a back guard for the lights.  It is a small piece of expanded metal that has a 25-30* bend in it.  It will protect the lights from being hit by items in the rack.  It still needs to be trimmed and welded in.Test fit on the 4Runner:Another pic:The floor will be next...Cheers,tpwww.tompenningtonphoto.com
Reply:Those are some great looking racks.Patriot Performance AutoLincoln Power Mig 255CLincoln AC-225 StickVictor Journeyman O/AQuincy QT-5 Compressor
Reply:Looks good.  Where did ya order the dies for the bender?DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Originally Posted by littlefuzzLooks good.  Where did ya order the dies for the bender?
Reply:Originally Posted by waveriderThanks!  I order the dies from a tooling company in Dallas that handles Hossfeld benders.  I researched the correct part # on the Hossfeld site and placed the order over the phone.  The dies were drop shipped directly from Hossfeld.  I couldn't find anyone that had the correct die in-stock.Cheers,tp
Reply:The pro tools dies are cheaper, but I already had the Hossfeld bender in the shop.  I just needed the 3/4" square dies.Cheers,tpwww.tompenningtonphoto.com
Reply:that sucks, I guess I'm just gonna have to break down and spend the money DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Originally Posted by littlefuzzthat sucks, I guess I'm just gonna have to break down and spend the money
Reply:I don't think those seem expensive, until you make a set.  I made a set of roller dies and the steel is probable near 100 dollars.  Then, turning and hardening.  Concave turning tools are not standard tool in most machine shop either.
Reply:Looking good man.. I made one for my 4Runner as my second welding project... the hardest part was figuring out where to drill the holes in the fiberglass to attach the mounts!No good photos on hand, but here are a couple quick ones i have in a photobucket account.meh