In my metalworking shop class this year, we have been given the oppurtunity to create any project we want, as long as we have a full set of step by step plans and a prototype. We are only being graded on production, so i have decided to fab up a roof rack for my 99 XJ. I have been following many awesome threads on here for creating different rack designs but I am curious if anyone has made one or if it is even possible to make one out of aluminum opposed to steel. simply for the cost and less weight. I feel like a steel square stock rack will be too top heavy? Any ideas? Thoughts? I know if aluminum is used i will have to TIG weld which i am certified in so it will not be an issue.If this is more suitable for Chat, please move i wasn't quite sure.

I would say that aluminum is fine. The stock rack is all aluminum and can support a lot of weight.

Can aluminum be coated? i was going to coat the rack inbed liner. Also, will it hold a full size spare safely?

yes and yes if you design it right. mine is made out of some "weak" conduit and it hold my spare, full camping gear, cooler included full of food, water, ice, and myself jumping around on it to tie things down for the road trip. i would say the proper aluminum will do just fine. of course you dont want to get anything too thin

Surco racks are made out of aluminum and they're pretty strong

also this should be moved since your not fabricating anything yet. wait until you start doing the work them post it up in here.

You sure ask a lot of questions about aluminum for being a certified TIG welder? lol

Im sorry thats not playing nice...

But,

Aluminum is the way to go if you can engineer the rack design well and know how to weld it. As stated before, the lightness of it would be great, but also the great corrosion resistance. And you can coat it with anything you like, but it may be good to etch it first for better adhesion or use an epoxy primer.

i dont think alluminum is gona be cheaper then steel.

i dont think that anywhere he was talking about it being cheaper as opposed to making a more suitable one with it being lighter than steel. heck if i could weld aluminum i would have made mine out of that instead just to keep the weight down especially it being that high up.

i made my rack out of #4 ReBar. heavy, yes. durable, yes. easy to mount, yes. awesome as aluminum, no.

thats the only reason i want one made out of aluminum....the awesomeness

do what i did i found a used surco with jeep mounts for 150.00 for my 95 xj then found a 2nd one for a 100.00 with gm mounts one is 45x60 the other is 45x50 all aluminum made and looks awesome...

oh buying them is no where near as fun or awesome as saying...."yup i built that there roof rack....mmmk"

ya in his first post he said because of cost and weight. i can weld alluminum and have thought about making one but i cant afford that much alluminum. its definatly a great idea. i hope it gets done.

I like the idea. My only suggestion would be to make the base ring and top ring out of 1" square tube with 3/4" square tube for the sides and floor. Maybe even 1/2" would work depending on the wall thickness and what you plan on tossing up there. Just remember that sometimes overkill is just enough to make you feel at ease.