How To Build A Roof Rack, Take One

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I'm reposting my tutorial for making overland roof racks;) naturally, this can be scaled up or down as needed. i did these many years ago.....

http://www2.mini-zracer.com/albums/roofrackhowto/rr01_5.sized.jpg

As with everything, starting with a plan makes things much easier. Or maybe it's the architect in me...I've drawn up plans for all the individual parts, quantities and sizes needed. If I’ve left anything out, just let me know...

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http://www2.mini-zracer.com/albums/roofrackhowto/rr01.sized.jpg

these are aome of the basic tools i use in making these roof racks. material include: 1/16"x1/16" brass tube, 3/32"x3/32" brass tube, aluminum wire mesh, 26ga copper wire, size 90-brass machine screws/washers/nuts

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http://www2.mini-zracer.com/albums/roofrackhowto/rr02.sized.jpg

The first things to make are the roof rails the rack will be sitting on. Using the 1/16"x1/16" brass tube, create bends with the lengths given in my plans. The overall length is 3"; so make sure you make the bends just inside that to take into account the width of the metal on both sides. Of course this all depends on how picky you are!

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http://www2.mini-zracer.com/albums/roofrackhowto/rr02_5.sized.jpg

The brass stock comes in 12" lengths typically. I always by one extra for screw-ups, because we all make them! Being the perfectionist that I am, measure twice cut once is my motto.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr03.sized.jpg

Next are the cross bars for the rails. Using the 3/32"x3/32" brass tube (the smaller size fits smoothly inside this size, you'll see why that's important), cut two pieces to the length in my plans. Please wear glasses when doing this; using the dremel and cutting wheel, cut out 1/16" of an inch on each side leaving a top and bottom flange. (Hold the tube parallel to the cutting wheel and cut into the tube end) Use the jewelers file to finish the job with nice square edges, I used the thin, flat one.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr04.sized.jpg

Now come the little stanchions that will hold the upper rack bar. Again, using the 3/32"x3/32" brass stock, cut six pieces to the length in my plans and like with the cross bars, use the dremel and cutting wheel to cut out a 1/16" on one end and drill a 1/32" hole as close to the top of the other end with out screwing up! It took me turning out a few duds to get it right. The important part is to drill the hole in the right side. The hole needs to be on the same side as the sides you cut out on the other end.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr05.sized.jpg

Now we come to the fun part! Soldering! Mmm, the smells of solder melting on the tip.... Always tin the part first, it makes the connections much easier to make and stronger. This is made easier by using a little flux (I use it on a cute tip). Apply a thin coat of solder on the bends of the rails. This will keep them from breaking; they cracked when I made the bends in them.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr06.sized.jpg

After tinning the end flanges of the cross bars, wedge them on either side of the rails and solder them together. This is why I cut out 1/16" on each side, they notch onto the rails now, creating a much stronger connection than just soldering a piece to the side of the rail. Be careful as brass is a good heat conductor, you can burn yourself holding onto the parts...hint, hint. Make sure you solder them as close to the ends of the rails as possible.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr07.sized.jpg

First, mark the rails where the stanchions will be placed. (Also in my plans) This part is where the needle nose pliers come in handy. Tin the flanges on the cut out ends. Wedge each notched piece onto the correct spot on the rail and solder them on. As a note, the holes should line up along the rail. If not you made one wrong.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr08.sized.jpg

Using aluminum wire mesh (stay away from the woven stuff, it's a mess to cut and deal with fraying edges) cut a piece roughly the size in my plans. It will be trimmed when fitted to the rack frame.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr09.sized.jpg

This is a rather mundane step, trim the wire mesh to fit nicely around the stanchions and cover the side rails and cross bars.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr10.sized.jpg

I know, the first thing you see is the cross beam, that wasn't in the instructions...I added this late to stiffen the frame. Cut a piece of the 1/16"x1/16" brass tube to fit cross ways in the frame and file the ends to fit snugly with the jewelers file. Ok, now cut some of the 26ga copper wire, strip the plastic off and use this to tie the wire mesh to the frame. The most efficient way is to loop the wire around, twist once and continue twisting using the needle nose pliers to get very tight twists. Once this is done, snip off the excess length with wire cutters.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr11.sized.jpg

To make sure the wire won't unravel, dab some solder on the twisted ends.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr12.sized.jpg

I took some these pictures out of sequence; so forgive me for the less completed work in the picture fame. Using the 1/32" brass rod cut two pieces to the lengths in my plans. I used to use two pieces, as it was the easiest way to slide them in, you'll see.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr13.sized.jpg

Slide the rods in through the holes in the upper stanchions (I’m not sure I have the right name for them?) and they will meet halfway inside the middle stanchion.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr14.sized.jpg

Liberally apply some flux and liberally solder the open ends of the stanchions. You can file down any large bumpy soldering later. Relax, almost done...

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http://www2.mini-zracer.com/albums/roofrackhowto/rr15.sized.jpg

Using the needle nose pliers, hold the size 90-brass machine screws and grind down one side of the screw head flat and grand down the slight bevel on the screw head top using the cutting wheel again with the dremel. Be very careful, if one of these catches on the cutting wheel, say goodbye to it...you'll never find it again. Good thing they come in bag of five, you've got one excuse to see one zip off and disappear!

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http://www2.mini-zracer.com/albums/roofrackhowto/rr16.sized.jpg

After tinning the head of the screws, hold the now flat side of the screw head against the inside of the rail foot and here's the tricky part, solder them in good. This is when you wished you had that third hand! Make sure you can still thread the nut o the screw and exhale, your done! It only took me about an hour and a half to two hours; with interruptions...Of course I already made one, so I have an advantage. Timing will depend on your fabrication and tool use skills. I'm sure it won't be difficult though. I tried to make a very uncomplicated design, kind of like Lincoln Logs...

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http://www2.mini-zracer.com/albums/roofrackhowto/rr17.sized.jpg

Ok, crack open the beer (if your of age) and revel in your newfound pride and accomplishment. The finishing touches are very simple. Paint with a primer, and put a few coats of black paint on it. The little cans of Testor spray paint work well and are inexpensive. Be sure to tape off the ends of the screws, the paint will make threading the nut on later a pain in the @ss.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr18.sized.jpg

Ok, so you're not done just yet...One thing left. To mark the placement of the holes, I placed the rack in the desired location and carefully traced the screw on the roof with my trusty pencil. Using the 1/16" drill bit, drill holes in the roof, I know it takes some force to get yourself to actually do this, but it's necessary. Do this by hand as very fast or forceful drilling will damage the plastic and paint. Make sure you go through the plastic window as well.

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http://www2.mini-zracer.com/albums/roofrackhowto/rr19.sized.jpg

You will have to fiddle with the holes to get a perfect fit. The round jewelers file comes in handy for this, or just use the drill bit. The hard part is threading the tiny, tiny washer and nut on the screw. You can tighten it with the needle nose pliers, don't over do it, you'll crack the plastic. And now you’re done! Enjoy, take pictures and share with the rest of us!

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http://www2.mini-zracer.com/albums/roofrackhowto/mz205.sized.jpg

With nice weather this weekend, I was able to do some painting. i generally use Testor spraypaints as they come in small and cheap cans. I put a nice primer coat on yesterday night. I thought I would try a primer coat first on this one as the paint on my first rack scratches off during nasty rolls etc. It's really not noticable though as I put something like 4 coats of paint on it.

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http://www2.mini-zracer.com/albums/roofrackhowto/mz206.sized.jpg

After two coats of black paint, I think I'm done with it. It looks much better when painted!