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.

Step 1: Step 1 of 6 - Concept and Finished Rack

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.

<p>Great job! Could the metal be painted black?</p>
<p>No it is against the law.</p>
<p>That's an ultimate roof rack :). What is the weight of that one? I'm looking for an idea of a good but lightweight rack and probably yours is going to be too heavy for my suzuki xl7 :)</p>
You did a nice clean build. That took time with the recessed bolt heads and all. Your corners were ingenious. Very nice work.
Thanks I spent a ton of time on it. but you know these projects are labors of love.
I'm finally getting around to doing this project and am wondering how the rack has weathered the last few years? Can you post a current pic?
It's been a while but the paint on the metal has faded quite a bit. Not much I can due but repaint.
cant send any photos just yet but the rack seems fine. The paint is peeling as it would on top of galvanized pipe.
ok so I took the auto correct off lets try again I used 1/2 emt it cost $70 I used curved corners and nuts and bolts it took me and my son one day to build to curve the ends we used a hammer and the floor took awhile but we did it again thanks for the idea
Glad to hear you had a successful finish.
By the way it only cost me 75 to build it
so I used your idea and made one from emt I used 1/2 inch and curved corners but I did bend them to hit over the emt no choice hammer and the floor took awhile but me and my son knocked it out in one day very fun project thank you for the idea we used it to go camping and it held ask the weight I put up there awesome thanks again
Nice Rack! lol, all kidding aside my brother and I came across this conduit about a year ago and love it. I bought a conduit bender and the possibilities are endless. I do have a welder, it really opens up the amount of projects you can make. A real bonus is the fact the conduit is galvynized so it is very rust-resistant.
<p>Just make sure you don't go welding any galvanized pipe - that's a sure way to poison yourself.</p>
Yeah, I love conduit, I don't have a bender so this is the way for me. Thanks.<br />
Neat idea. But the cheapest roof rack I found was $120 new 5 years ago. And they're cheaper if they are used. A $20 difference doesn't seem to be worth 10-15 hours of work. <br /> <br />
<p>nice ????</p>
It's not just about the cost but, for me, it's the challange of seeing if I can pull it off.<br />
I'm thinking about making a ladder rack version of this. I'll have to post it here when I do.
Thanks for this great post. I have been wondering about getting <a href="http://www.autopartstoys.com" rel="nofollow">rhino rack roof racks</a>. Any suggestions? Thanks.
I love this method of making a <a href="http://www.autopartstoys.com" rel="nofollow">rhino rack roof racks</a>. Its always fun to come across really good ideas that you would actually be more than happy to try. I have in the past found what I thought would be good ones and didn't work out. I actually think that this works.
I don't have an idea if this truck roof rack is better than my roof racks ( from roof racks Direct ). It is not really expensive compare to the quality of other roof racks.
This is a really nice no nonsense roof rack, with excellent instruction. I have been looking for a no weld method I can use on my Jeep and will definately give this a go. Do you have a pic of the rack painted you could post? I give this finished project a 10! Great job and thanks for sharing.
indeed, it is a really nice roof rack and great instructions. Mr Chuck as you used it already just wonder if it create any wind whistle at high speed. If not i will definitely build one for my VW BayWindows. Besides, i will consider your set-up to build a roof-top tent for camping. it will be really nice on my restoration project. I will share it with both of you soon as i completed it.
Thanks MrChuck, Just make sure that you use plenty of rivets. Sorry, no pics of it painted black but it really helps.<br><br>Thanks again, Graphicsman/Toolman
excellent work!!! but may i ask if it create load wind whistle and additional vibration when you are on road?
I'm going to make one of these very soon. Thanks graphicsman!<br>
I wonder which is better/easier/stronger? The welded pipe bent or the smashed riveted? Either way, yours look really great!<br />
I have been looking for a good no weld roof rack build and I just found the best one so far! I am building a roof rack for my Datsun 1200 coupe and I think I will use this method.
Very nice solid looking rack.&nbsp;<br /> Great job.<br /> Mark
Thanks. Could you rate it?<br />
Very well done, nice looking and seems better than most commercial racks.<br />
I wasn't going for taht but it took some of the design ques. Thanks<br />
&nbsp;Looks quite professional!
Thanks.<br />
I really like it... <br />
Thanks.<br />
definately looks sturdy. Well thought out project and &quot;ible&quot; . I would think a couple of eyebolts would make tie downs easier but with all the tie off points they're probably not needed. Does it make any whistling noises when your on the hiway?
I don't know, I'll get back to you when I use it more often. Thanks.<br />

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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 ... More »
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