No Weld Truck Roof Rack
Intro: No Weld Truck Roof Rack
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.
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.
STEP 6: Step 6 of 6 - Completion and Mounting
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 close, you can see a piece of 1/2"plywood that attaches to the bottom rack rails and the existing rack bars.
Several steps left to do like:
Disassemble the wood floor and give them another coat of exterior varnish.
Paint the rack black.
Remount the floor.
Remount the rack to the truck.
Let me know what you think.
emailthetoolmanshow@gmail.com or emailthetoolman@gmail.com
Several steps left to do like:
Disassemble the wood floor and give them another coat of exterior varnish.
Paint the rack black.
Remount the floor.
Remount the rack to the truck.
Let me know what you think.
emailthetoolmanshow@gmail.com or emailthetoolman@gmail.com
41 Comments
Duke4857 3 years ago
thetoolman 3 years ago
ReverendSapp 14 years ago
jeff 9 years ago
Just make sure you don't go welding any galvanized pipe - that's a sure way to poison yourself.
DennisH45 7 years ago
True, good point, as the zinc used with galvanized creates a toxic fume which results in a fever. Weld it outside and use a very good fan to direct the fume away. Otherwise, you'll feel like crude for a few days. I like using conduit, too, and am considering to fabricate a 38 foot truss bridge with the stuff.
thetoolman 14 years ago
jamesk891 8 years ago
myke2020 8 years ago
Great job! Could the metal be painted black?
NickS21 8 years ago
No it is against the law.
AndreyP2 8 years ago
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 :)
ScootersDenver 9 years ago
thetoolman 9 years ago
ogmosic 10 years ago
thetoolman 9 years ago
thetoolman 10 years ago
dsmith178 9 years ago
thetoolman 9 years ago
dsmith178 9 years ago
dsmith178 9 years ago
chuckr44 14 years ago