GetupnGo

I just just drew this up on SolidWorks today. Been wanting to make one for those crowded camping trips and wheeling trips. I plan on fabbing it up in the next two weeks. I figured since i have the ability to see it in 3D and change anything i don't like before i actually build it i'd post on here and see what y'all thought. So how can i make it better? Give me your input and let's ALL make the best homebrew roof rack out there.

I plan on adding some eye bolts to bottom of the top tubing for straps and such. also, i will add hooks and mounts for shovel, axe, etc. onto the side.

Now, how we gonna mount it? good question. I'm really not a fan of gutter mounts at all and don't like the way it looks when the rack is just as wide as the xj. So, right now i plan on using the existing roof rails or if i feel they are not strong enough i will remove the roof rails and put a more secure system on the roof. I could possibly be talked into gutters but really don't like that option as previously stated.







also, I am going to weld an 1/8" expanded aluminum sheet on the bottom as the "floor"

all the tubing is 6061 aluminum 1"OD x 0.125" wall.

So bring it on guys. I like the look I've got so far but i know all of you are much smarter than me and always have some clever ideas.

kelly4

I really like the fairing! Normally I'm not a huge fan of smaller racks like these but this one looks really well thought out. Whether or not to use gutter mounts or the factory roof rails depends a lot on how much weight you'll have up there. Gutter mounts can definitely take more weight but most of the ones I've seen are used with wider racks...perhaps you could fab up a gutter mount that's longer so your rack doesn't have to be so wide?

MilwaukeeJeep

what is solidworks?

GetupnGo

SolidWorks is a Computer Aided Design (CAD) program that engineers use to make 3D models of their designs, parts, or projects before they actually build anything. It allows you to make theoretical assumptions about your design.

SolidWorks also has features that allow you to do stress analysis on a part. For instance, i can "load" my roof rack on solidworks with 300 pounds (or any other weight i wanted). Solidworks will then show me how stressed each member of the rack is. It will also show how much the beams across the bottom will deflect, or bend downwards. So if i dont have enough strength to hold 300 pounds i will know before i build it.

Thats just the tip of the iceberg when it comes to CAD though. Its uses are limitless. The company i work for uses SolidWorks to design fiberglass and carbon fiber unmanned aerial vehicles for the military. We design a fuselage, wing, landing gear, etc, plug that model into our CNC Machining Router and out comes an airplane. pretty neat stuff.

the only problem is... its really expensive. so unless you work somewhere that has it or you go to a university with a a cad software, its kinda hard to get your hands on. Fortunately, im blessed to have the ability to use it and make stuff because of it.

-GetupnGo

RandyLahey

Really clean rack! I love using SolidWorks for anything really. If only I could fab up half of the things I dream up in Solidworks, I'd be set.

Also you might have already found this, but you should fix that intersecting geometry before you try and FEA it. You can extrude "up to surface" in both directions, that would make it perfect.

EDIT: just saw your profile pic, You're on the Auburn SAE team? so wicked man, you guys had a really nice car this year. I'm on the SAE team at the University of British Columbia. Disregard what I said up there, I'm sure you know how to use Solidworks pretty well haha.

JandDGreens

Can you build one for me?? My son and I built a rack for his XJ. We had a lot of fun putting it together. We decided to use the existing rails and since it was a full length rack we added an extra rail. I used channel bar to go across so that it is flat for the rack. His will hold as much weight as one can feasibly put on it.