Finally finished, it's time to mount it to the truck and test it out for weight. I drilled holes in the existing bars and bolted it down. If you look ...
I've always wanted a rack for my pickup buy didn't want to pay the high price and thought I could build my own out of electrical conduit. I've used this material before for lots of things and wanted to give it a shot. I don't own a welder so that was out of the question. I settled on a straight forward design with 2 horizontal rails, uprights and diagonals and a wood slat floor. I also wanted to keep the cost around $100. in materials. It took me several weeks of a few evenings in the shop to fabricate it. Let me know what you think.
I wanted a rack that would bolt to my existing roof rack. It's a Dodge accessory and just 2 horizontal bars that run in a track bolted to the roof so it's a good strong base to start with. If you don't have one, get one as your base. THIS RACK IS NOT MEANT FOR SUCTION CUPS.
Step 2: Step 2 of 6 - Making the Verticals
This step describes the fabrication process for all of the tubing connections involving cutting, bending and grinding. I used a 4" cutoff wheel on my hand held grinder because it was faster and easier than a hack saw. In terms of the vise, you'll need the biggest one you can get because smaller ones won't hold up, and use a length of pipe for leverage.
Step 3: Step 3 of 6 - Making the Horizontals
On to the horizontal frame. When formulating the design, I wanted a clean corner that just wasn't some bent tubing and I found these cool pull through connectors that provided function and clean design.
Step 4: Step 4 of 6 - Joining the Frames with Verticals
Here we see the horizontal frames joined using the vertical pieces. Again, 3 pop rivets to each connection. I found a deal at Harbor Freight on a box of 500 rivets for $3.
Step 5: Step 5 of 6 - Adding the Wood Floor
The floor is made from redwood fence boards that I ripped in 2 pieces and planed down to 5/8" thick to minimize the weight. Each is attached with 4 1/4" bolts and special nuts that don't come loose. I found the hardware at the local home center.
Bio:a.k.a. "The Toolman" has been creative and worked with his hands all of his life. He has been employed in a wide variety of industries including a museum, a major power tool manufacturer, a national v...read more »