Aluminum Roof Rack
Thread Starter
CF Veteran
Joined: Feb 2010
Posts: 3,353
Likes: 1
From: Missoula, MT
Year: 1999
Model: Cherokee
Engine: Golen 4.6 Stroker, AFE Headers, 62mm TB, 24 LB Injectors, Brown Dog kit, HF Cat, 3" Exhaust
Aluminum Roof Rack
I built a steel roof rack two years ago-
Which worked great but had a few problems I didn't like. For one, I did not factor the curve of the roof so it say quite a bit taller than expected. For two, It was heavy (about 80lbs). It held a deer, 3 people at once and was plenty strong but realistically, more beefy than I needed.
So enter version 2.
I have not had a chance to weld it yet (hopefully this weekend) But it will arc with the roof (The center is 3" higher than the edges), only weighs 22lbs, will have a light bar mounted in the front and is much more symetrical. Overall, it will be about 4" shorter.
I am going to paint the frame and brush the plate then clear coat it all. I'll post back some more when it is done! It will also mount via gutter mounts
Which worked great but had a few problems I didn't like. For one, I did not factor the curve of the roof so it say quite a bit taller than expected. For two, It was heavy (about 80lbs). It held a deer, 3 people at once and was plenty strong but realistically, more beefy than I needed.
So enter version 2.
I have not had a chance to weld it yet (hopefully this weekend) But it will arc with the roof (The center is 3" higher than the edges), only weighs 22lbs, will have a light bar mounted in the front and is much more symetrical. Overall, it will be about 4" shorter.
I am going to paint the frame and brush the plate then clear coat it all. I'll post back some more when it is done! It will also mount via gutter mounts
Thread Starter
CF Veteran
Joined: Feb 2010
Posts: 3,353
Likes: 1
From: Missoula, MT
Year: 1999
Model: Cherokee
Engine: Golen 4.6 Stroker, AFE Headers, 62mm TB, 24 LB Injectors, Brown Dog kit, HF Cat, 3" Exhaust
I have access to both but being as it is .125 tubing and .100 plate, I am going to go with the TIG. I just have to grab some argon and fit time in. Shouldn't be long!
We had a 4x8' piece of aluminum expanded laying around at work that I picked up for the bottom as well.
The best part? Being as I get everything at cost and use the equipment for free, the plate cost me 16.75$, all the tubing cost me 22$, and the expanded was 38$. Pretty cheap for an aluminum rack haha.
We had a 4x8' piece of aluminum expanded laying around at work that I picked up for the bottom as well.
The best part? Being as I get everything at cost and use the equipment for free, the plate cost me 16.75$, all the tubing cost me 22$, and the expanded was 38$. Pretty cheap for an aluminum rack haha.
Last edited by Ianf406; Feb 18, 2017 at 09:44 AM.
Seasoned Member
Joined: Mar 2015
Posts: 473
Likes: 8
From: Oregon
Year: 2000
Model: Cherokee (XJ)
Engine: 4.0 I6
I have access to both but being as it is .125 tubing and .100 plate, I am going to go with the TIG. I just have to grab some argon and fit time in. Shouldn't be long!
We had a 4x8' piece of aluminum expanded laying around at work that I picked up for the bottom as well.
The best part? Being as I get everything at cost and use the equipment for free, the plate cost me 16.75$, all the tubing cost me 22$, and the expanded was 38$. Pretty cheap for an aluminum rack haha.
We had a 4x8' piece of aluminum expanded laying around at work that I picked up for the bottom as well.
The best part? Being as I get everything at cost and use the equipment for free, the plate cost me 16.75$, all the tubing cost me 22$, and the expanded was 38$. Pretty cheap for an aluminum rack haha.
