When it was finished, this was the business. Wood and steel, cant go wrong. Ive used it loads of times, solid as rock.
[Added]In use: It takes 5 mins to load the windsurfer and is stable at 60mph, which is the fastest Ive gone.
Step 1: List of Materials/Cost/Tools/Time
Total construction time : 1.5 days. It took me about 8hrs actual work time, but I needed to let glue and paint dry
Step 2: Cutting Wood
I made sure that the length of the wood allowed it to sit in the back of the car when not in use. Although you could leave it on the roof when windsurfing.
Step 3: Getting the Curves
So using a bit of scrap wood and a marker, get the shape of the roof - see the picture. Suggest you mark the front, it can get confusing otherwise.
Next you need to curve the ends, I used my coffee cup that just happened to match the curve I needed. Draw round your mug (the cup, not your face!)
You only have to do this once, the second wooden runner is cut from the first.
Step 4: Cut the Curve
Using your trusty jigsaw cut out the curves. And then sand to shape.
Check it on the roof, from time to time, make sure its accurate.
It doesnt have to fit to the millimeter, a layer of plastic foam is going to provide an extra layer of comfort. I was in a hurry to get to the lake, but it was a pretty good fit.
Step 5: Cut the Holes for the Pipe
Anyway, using a three quarter inch drill spade (to match the pipe width) cut the holes half-way thru the wood.
Step 6: Cut the Pipe to Length
I used a grinder to cut the pipe.
Step 7: Assemble It All
You put the pipes into the holes, test it on the car, ok, looks good, then using construction glue fix it in place.
The glue takes a while to set, overnight worked fine for me.
Step 8: Fibreglass the Pipe Joints
This only took about 30 mins, the nature of working with fibreglass is that it sets quickly, and Im sure a smoother job could have been done if you spend a bit more time and effort on it.
Anyway the proof-is-in-the-pudding and its worked great for 4 months.
Step 9: Paint to Match the Car
Step 10: Put on the Rubberized Pipe
Step 11: Put on a Protective Plastic Foam
I thought gluing foam onto wood would not prove resiliant to the weather, pressures and movement, but Ive been proved wrong - luckily.
Step 12: Setup on the Car
- Place the rack on the car
- Put the windsurfer on it
- Strap the whole thing down attaching the hooks of the web straps inside the car to the roof handles.
- Jump in the car, get to the lake and windsurf
Note: I made it so that the rack fits in the back of the car
Ive been using it for 4 months now, shame its the wrong color. You will probably notice that I have a sun roof which is another problem with standard roof racks. Also, I tend to move the back strap up a bit so it goes over the wood (like the front one). This picture was taken at dawn waiting for the sun to come up so I could nip down to the lake.
Other cars? OK so this is a Honda Civic, the roof is incredibly curved and its not rectangular, and very wide, so I reckon any other car should be easier. Enjoy