How To Build A Jamboree Rack

[arch2b]

Like the roof racks, i made this tutorial years ago. I'm reposting it here incase anyone would like to see how i made one for my overland. these too can easily be scaled up or down as needed.

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0339.sized.jpg

this is my first attempt at making one of these, which was a suggestion of a forum member. i began with the same materials i use for roof racks.

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0340.sized.jpg

my idea was to adapt the stanchion form from the roof rack to be the bottom platform for the jamboree rack. so i decided that it would be 1/2" wide or off the back of the pajero and fit ontop of the bumper lip and inbetween the bumper side molds. i cut the corners and bent the rod to form an elongated "c" shape (this will be explained in later steps)

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0341.sized.jpg

with the bottom frame done, i cut 2 peices 1/2" tall to form corner stanchions and support the top frame.

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0342.sized.jpg

i cut 1/16" corner notch off the 2 1/2" corner stanchions that you can see here. (this will be explained in later steps) i next bent the smaller rod to form the back of the box frame and top rail. you have to measure carefully so the smaller rod sits on the bottom frame and still stays within the 1/2" height. then bend the top frame corners that will rest in the corner notched corner stanchions.

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0343.sized.jpg

the hard part is soldering the corner stanchions in the bottom frame ope corners so the stand up striaght and true. also i soldered the bent corners of the top frame as well.

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0345.sized.jpg

i added the caution decal and the tinyrc bumper decal a long time ago. i wanted to take a picture of them since i now won't be seeing them anymore

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0346.sized.jpg

using the same technique, i soldered the mounting screws into the legs of the bottom frame. this is much harder since the overall size of the peices to manage is much smaller than the roof rack

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0347.sized.jpg

now some of the earlier design ideas can be seen such as the notched corner stanchions to hold the top frame and the cut instead of just bent corners of the bottom frame to hold the corner stanchions

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0349.sized.jpg

i completely forgot to add a cross bar along the back to give the rack a box frame for the wire mesh. just cut a section and solder in just forward of the back legs of the top rail. this is very important as it leave a gap to allow the wire mesh to conform to the curavture of the rear of the truck

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0350.sized.jpg

using the same wire mesh, cut an slightly larger size peice and trim to fit the bottom box frame

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0351.sized.jpg

using the solid copper wire make the same wire ties as on the roof rack to tie down the wire mesh and twist tightly

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0352.sized.jpg

once the tie downs are twisted, solder the copper wire slightly, trim off the excess and push the nubs left into the frame opening to prevent them from catching on anything

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0353.sized.jpg

align the rack and drill the 2 mounting holes just above the bumper lip

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0354.sized.jpg

using the wrench you can get with the screws/nuts/washers, turn them to hand tight. you don't want to pop them out of the bottom frame legs

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0356.sized.jpg

take care threading the antenna thru as you put the body back on the chassis and your done!

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0357.sized.jpg

since this is a prototype, it may appear plain but i plan on revising the design now that i have one done

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0358.sized.jpg

you have to make sure the screws are soldered in at the correct angle or the rack will tilt back. as you can see, mine is nearly perfect.

[arch2b]

http://www2.mini-zracer.com/albums/album125/IMG_0363.sized.jpg

i'm not sure what to put in this thing but it looks neat. a couple of jerry cans would be nice