How hard would this be to build for a beginner?

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I bought a Hobart 140 about a month ago and I built my welding table. Learned alot doing that but still very new. Had my share of bad looking welds, a couple burn throughs and out of square areas. I am looking for my next project. I have a 2012 Nissan Frontier with a utilitrac bed rail system and would love to make something like this for it. We are going to the Outer Banks this summer and would like to be able to mount our luggage carrier to the top of this thing and still store stuff underniegh. I can't paste pictures because the site wont allow it but I have attached a link. They are selling this thing for $900!!! I should be able to make it for considerable less! Any idea what size and how much steel I would need? I have a 5 ft long bed and its about 4 Ft. across I believe. If anyone is in the Maryland area and would like to give me a hand with this let me know! http://www.xterraperformance.com/FRO...ier_p_210.html
Reply:You can figger out the amount of steel 16g 1" sq tubing will work just fine for this.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I could make that rack.   That means you can too.     Whether it is cheaper depends on how greedy they were and how well you build AND finish it.   Don't forget that you have to protect the steel from rain, road salt, etc.   A good paint job or powder coat is a great idea.The amount of steel depends on your dimensions.   I'd start a project like this by making a drawing with all the pieces in their proper relationships.   It does not have to be dimensionally correct since you are just wanting the count and length of each piece.I made an oven rack (similar idea to yours on a smaller scale) just because I could.  It cost around $20 in materials.   I could get one online for $25, but the one that matched my design was $75 plus shipping.  ----------------------------Measure twice.  Weld once.  Grind to size.MIG:  Lincoln SP100 TIG/STICK:  AHP Alphatig 200X
Reply:http://www.lowes.com/pd_109068-53911...ductId=3284278Apparently these will slide right in to the Nissan Utilitrack system. All ya need to do is fab up the plate on the Cargo Rack and the run a bolt through the plate into the Spring Nuts.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by Broccoli1http://www.lowes.com/pd_109068-53911...ductId=3284278Apparently these will slide right in to the Nissan Utilitrack system. All ya need to do is fab up the plate on the Cargo Rack and the run a bolt through the plate into the Spring Nuts.
Reply:I would use square tubing too.  The flat bar will sag unless you use really thick steel.  Try this old trick for the brackets.  Mock up the cage part and hold it where you want it ( must be in the center of your truck bed).  Use some cardboard strips (to mock up the brackets)and trim them until they fit.  They will match the angle of the truck bed and the angle of your cage part.  Transfer the cardboard templet to whatever steel you are going to use.  Cut them the all the same.  You don't even have to measure the angles.  If you use square tubing to bolt to the truck you will want to put a bushing in the tube so you don't crush the tube with the bolt.  Or drill a bigger hole( large enough for a socket) on one side of the tube and a hole just big enough for the bolt shank on the other.  The idea is you reach trough the tubing with the bolt and when you tighten it, it won't collapse the tubing.  I hope you know what I mean.
Reply:What Angus said- Flat bar will sag.  The one in yer link is extruded Aluminum Tube- even though it looks flat- the Tube structure gives it strength.You don't have to angle the Brackets- that's just the way they designed theirs.http://www.usrack.com/images/Dual%20...ck%2092DPI.jpgThis ladder rack bracket looks like it goes straight down off a piece of angle.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Where in MD are you?Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I would design it for the purpose of holding the luggage rack if that is all you will use it for.  It will only be single purpose, but it will really cut down on the weight.  No need to haul around 150 lbs of steel if you don't have too.  things like this get heavy real quick. It will  also cut the cost considerably.Syncrowave 210HH140Victor O/A
Reply:Thanks for the great explanation! I an a visual person though. Having trouble picturin what u r saying. Any pics?
Reply:I am in harford county maryland.....
Reply:Originally Posted by mpbclutch33Thanks for the great explanation! I an a visual person though. Having trouble picturin what u r saying. Any pics?
Reply:I saw that one and think that may be the better Option. I just liked how the other one raised it up a bit more to allow for more storage underneath.
Reply:Just make the risers taller Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:On the 2nd design with the Square tubing..... How would those mounts be made? It doesn't look like (2) pieces of flat stock welded at 90degrees unless it is just large angle iron???
Reply:Looks like two pieces to me.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:As others have noted, I too would absolutely go with light gauge tubing for this project.It may benefit you to jig the legs into position before welding everything together to help control your warpage and ensure that it fits after welding. This could be as easy as tacking the legs to the table before welding or as complex as re-creating the bed pockets in your shop. If yer just making one, I would do to the most simplistic but effective method.. any more than one and a jig gets made! You still may have to do some light manipulation, but the less that you have to do after welding the better!
Reply:I would make it from old bed frames.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:Can you weld aluminum? Steel is going to add up to some weight.
Reply:Originally Posted by Broccoli1You can figger out the amount of steel 16g 1" sq tubing will work just fine for this.