DOM roof rack/platform - Jeep Cherokee Forum
Jeep Cherokee Forum


Fabrication builds section. All fabrication posts go here.
XJ/MJ/ZJ/WJ Only projects go here. Questions belong in modified tech.

DOM roof rack/platform

Reply
 
 
 
Thread Tools Search this Thread
Old 05-26-2016, 03:57 PM   #1
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default DOM roof rack/platform

For a while now I've wanted to make a platform for the top of my XJ. The interest was for two reasons. One being a space to camp out or simply use as a spectator's platform and the other to link it in to a hatch mounted tire carrier. I'm not a fan of the swing out carrier types nor do I have really any interest in hauling gear up there - so a basket is not what I'm after. So for this build, I aimed to make it as low profile as possible, slightly hang outboard enough to serve as a tree rub rail and maybe eventually tie in an internal cage down the road.

I'm not done yet, but far enough along to show what I'm doing and maybe motivate myself to keep after it.

The det's of the build are as follows: 1.75x0.095 wall DOM tube / 2x2x0.125 angle iron / JCR gen I gutter rail rack brackets. I'm planning to deck with 12GA perforated sheet but not for sure. Trying to keep weight down.

On with the pics!

Hoop bent up and welded - this is a 23' stick simply cut in two and bent to match each other. Sort of works out perfect.
Name:  F9C0D765-33EA-4962-A82C-EDC052D9F10A_zpsyji17xg6.jpg
Views: 0
Size:  213.8 KB

Name:  73121607-A913-433C-B7B3-96B6CFA01B23_zpscoilkplo.jpg
Views: 0
Size:  223.8 KB


After a bit of notching and drilling, I finally get the 2" angle iron to follow the form of the roof. Forgive the shooty pic.
Name:  A2BC99F0-2051-48A3-9FBD-CF377E99336A_zpswebgbgzs.jpg
Views: 0
Size:  107.4 KB

You can see here with the angle iron notched for the tubing that there is a fairly significant bow to the top of an XJ. I cut 4 slits in one leg of the rail, bent it to follow the curve of the roof and then welded them back closed.
Name:  38992AED-201C-4B4F-82B4-D3CE6B279051_zpsgduoubmf.jpg
Views: 0
Size:  225.4 KB

Name:  AA791A33-8864-446A-A7B6-AE8EC7A9C4BB_zpsajjgnhuq.jpg
Views: 0
Size:  219.4 KB

Closed and miter cut the angle ends.
Name:  BC2D7AAF-ADC5-45D0-B5C9-52F4D3AF2835_zps8whkubhv.jpg
Views: 0
Size:  152.3 KB

Refitted to the truck and mocked in the tabs.
Name:  1C41E293-2BF1-4169-A0E3-26682625DD4A_zpsezn89ncb.jpg
Views: 0
Size:  187.9 KB

I'm not actually liking that they'll stick outside of the rail, so tonight I plan to cut these down so they're more underneath the rail rather. I think it'll look better too.
Name:  3EBD2CCE-BE99-45E6-813D-36720B531FBA_zpsct5fnj6k.jpg
Views: 0
Size:  154.7 KB

Here's the clearance at the hatch when it's open. This shows why it looks almost shoved forward a bit. I think it'll all come together once I add the hatch mount tire carrier.
Name:  D902C4A9-4E1D-4B4E-AC57-03D649744385_zpszrqr0ftw.jpg
Views: 0
Size:  180.4 KB

Name:  80A57549-A7FA-4E27-943C-3F0EC5E1DD3A_zpsjdz4o2yd.jpg
Views: 0
Size:  211.8 KB
Name:  AE0A20C3-DE9B-47DA-8FAB-22ED86AD4767_zpsgu2jwpmb.jpg
Views: 0
Size:  232.6 KB
s14unimog is offline   Reply With Quote
Old 05-26-2016, 05:21 PM   #2
HUH? WHAT?
 
XJwonders's Avatar
 
Join Date: Jan 2013
Location: west chester, pa
Posts: 17,329

View XJwonders's Photo Album My Photos
Default

Very nice!
XJwonders is offline   Reply With Quote
Old 05-26-2016, 07:43 PM   #3
Senior Member
 
TwistedWrench's Avatar
 
Join Date: May 2015
Location: San Antonio, TX
Posts: 885

View TwistedWrench's Photo Album My Photos
Default

Subbed, very cool. I've though about the hatch-mounted spare too, just concerned about the weight with a 33.
TwistedWrench is offline   Reply With Quote
Old 05-26-2016, 08:00 PM   #4
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default

Quote:
Originally Posted by XJwonders View Post
Very nice!
Thanks man
Quote:
Originally Posted by TwistedWrench View Post
Subbed, very cool. I've though about the hatch-mounted spare too, just concerned about the weight with a 33.
It's definitely a concern here too. I've got a few ideas I want to at least throw a try at it before I convince myself it shouldn't be done though.
s14unimog is offline   Reply With Quote
Old 05-26-2016, 08:12 PM   #5
Senior Member
 
TwistedWrench's Avatar
 
Join Date: May 2015
Location: San Antonio, TX
Posts: 885

View TwistedWrench's Photo Album My Photos
Default

Quote:
Originally Posted by s14unimog View Post
Thanks man

It's definitely a concern here too. I've got a few ideas I want to at least throw a try at it before I convince myself it shouldn't be done though.
Yeah, my first idea was just super heavy duty struts, but I'm afraid the strain could damage the hatch. At least ours don't have the 'glass hatch, but still.

I really do like the idea of the spare on the back while having easy access into the rear area(lol, bazing!). I may pick up an extra hatch and play around with reinforcing it from the inside.
TwistedWrench is offline   Reply With Quote
Old 05-26-2016, 10:48 PM   #6
TIME TO GET SCHWIFTY
 
roninofako's Avatar
 
Join Date: Feb 2011
Location: Apple Valley, CA
Posts: 11,052

View roninofako's Photo Album My Photos
Default

Quote:
Originally Posted by XJwonders View Post
Very nice!
X3, nice work
roninofako is offline   Reply With Quote
Old 05-27-2016, 06:23 AM   #7
Junior Member
 
Lowrange2's Avatar
 
Join Date: May 2008
Location: +34 25' 35.67", -81 21' 12.04"
Posts: 14,749

View Lowrange2's Photo Album My Photos
Default

Looks good. I like that you're using the factory roof rack mounting points. I saw someone else do that a good while back on a WJ and that's what I plan to do if I ever manage to build the rack that I want to build.
Lowrange2 is offline   Reply With Quote
Old 05-27-2016, 08:23 AM   #8
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default

Quote:
Originally Posted by roninofako View Post
X3, nice work

Quote:
Originally Posted by Lowrange2 View Post
Looks good. I like that you're using the factory roof rack mounting points. I saw someone else do that a good while back on a WJ and that's what I plan to do if I ever manage to build the rack that I want to build.
Yeah man, I was a little worried about simply using the gutter rails alone. What's cool is how sturdy it feels bolted down to just those rack mounts. I had a buddy jump up on top of it and stand out on one of the front corners - basically standing over the corner of the windshield and I didn't see any deflection in the roof. After this, I encourage everyone to use those mounts and only have the gutter rail mounts as backups/support.
s14unimog is offline   Reply With Quote
Old 05-31-2016, 07:59 AM   #9
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default

Gutter rail mount tabs burned in. Luckily we've been without rain, so I haven't had to take it down yet. I'm shooting to knock out the deck material and hatch carrier pivots before the weeks out - I got the tabs and bushings from Ruff Stuff Specialties. How many cans of Rustoleum do you think it'll take...?

Name:  A4F98BBF-D933-4346-9FB5-8729F83C909C_zps6fc5vvxz.jpg
Views: 0
Size:  152.2 KB
Name:  72BA9BD5-5B52-48B4-A530-70AD84A7C92A_zps3x5po5z5.jpg
Views: 0
Size:  181.9 KB
Name:  F2E494E5-73B0-47E0-BA92-9BEE34A6A71E_zpsfyfncwwv.jpg
Views: 0
Size:  187.1 KB


Also, the ol'girl finally rolled the big 200K - greeted by an airbag light
Name:  7F224BEE-D3C2-435F-939A-19611FF57B5C_zpsytrigwlu.jpg
Views: 0
Size:  106.1 KB
s14unimog is offline   Reply With Quote
Old 05-31-2016, 09:56 AM   #10
Senior Member
 
CR-Snow's Avatar
 
Join Date: May 2015
Location: Louisville KY
Posts: 648

View CR-Snow's Photo Album My Photos
Default

Quote:
Originally Posted by s14unimog View Post
Gutter rail mount tabs burned in. Luckily we've been without rain, so I haven't had to take it down yet. I'm shooting to knock out the deck material and hatch carrier pivots before the weeks out - I got the tabs and bushings from Ruff Stuff Specialties. How many cans of Rustoleum do you think it'll take...?







Also, the ol'girl finally rolled the big 200K - greeted by an airbag light
Man this looks awesome! Using the angle to bolt to the factory rails mounts is very slick.

What kind of bender are you using for the Dom? And what kind of welder. Subbing this one for sure.
CR-Snow is offline   Reply With Quote
Old 05-31-2016, 10:56 AM   #11
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default

Quote:
Originally Posted by CR-Snow View Post
Man this looks awesome! Using the angle to bolt to the factory rails mounts is very slick. What kind of bender are you using for the Dom? And what kind of welder. Subbing this one for sure.
Thanks! I'm using a Rough Fab bender and am welding with a 220V wire feeder on a 75/25 bottle.
s14unimog is offline   Reply With Quote
Old 05-31-2016, 09:28 PM   #12
Senior Member
 
TwistedWrench's Avatar
 
Join Date: May 2015
Location: San Antonio, TX
Posts: 885

View TwistedWrench's Photo Album My Photos
Default

Man, it's coming along great, looking good
TwistedWrench is offline   Reply With Quote
Old 06-01-2016, 08:38 AM   #13
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default

Quote:
Originally Posted by TwistedWrench View Post
Man, it's coming along great, looking good
Thanks dude

Ruff Stuff brackets came in and I got some hardware together. These are the pivots for the tire carrier tie in to the rack. I'll say, as simple as a plasma cut tab can be, these are done really well. The bolt hole tolerances on the tabs are probably .010" over the nominal, the start/stop initial cut marks are in a consumable location and the taper on the side of the tab is practically non-existent. They almost look laser cut, but I think they're just done on a beefy plasma. Either way, great attention to detail. Can't wait to burn them in.

Name:  314F97B9-F862-4C84-BA93-2F7FC8B7D610_zpsshhjjhkx.jpg
Views: 0
Size:  164.9 KB
s14unimog is offline   Reply With Quote
Old 06-01-2016, 11:12 AM   #14
Senior Member
 
CR-Snow's Avatar
 
Join Date: May 2015
Location: Louisville KY
Posts: 648

View CR-Snow's Photo Album My Photos
Default

I really like how it overhangs the front a bit. I'm putting together a welding rig right now but it's coming along slowly. Only have access to 110 volts at my house. That Dom looks pretty big. And being a total newb to welding, I'm not sure if a 110 could weld that stuff. I've also been contemplating an EMT rack.

Can't wait to see the finished product.
CR-Snow is offline   Reply With Quote
Old 06-02-2016, 08:19 AM   #15
CF Veteran
Thread Starter
 
s14unimog's Avatar
 
Join Date: Dec 2009
Posts: 1,395

View s14unimog's Photo Album My Photos
Default

Quote:
Originally Posted by CR-Snow View Post
I really like how it overhangs the front a bit. I'm putting together a welding rig right now but it's coming along slowly. Only have access to 110 volts at my house. That Dom looks pretty big. And being a total newb to welding, I'm not sure if a 110 could weld that stuff. I've also been contemplating an EMT rack. Can't wait to see the finished product.
Yeah, you really should look at building an extension cord for an existing 220VAC hook up or get one run. Depending on your current panel setup, it could be really simple and cheap. The DOM I'm using is only .095" thick (so just over 3/32") - not very thick. I'm not a fan of that EMT tubing for this use, it's really just not intended for any sort of structural use. It'll work as a basket if that's what you're after, but I imagine due to the plating, it could be annoying to try welding with.
s14unimog is offline   Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
Fan Box Inlet Screen MtnHermit OEM XJ Cherokee Technical. All XJ Non-modified/stock questions go here 8 04-10-2016 08:13 PM
add ons nathanspooner Cherokee Chat 3 04-07-2016 09:15 AM
Tie End Rod Question Batman33165 MODIFIED XJ Cherokee Tech 7 04-06-2016 01:36 PM
tires/wheels erikfoxx55 KL Cherokee Tech 0 04-05-2016 06:54 PM
Build Sheet Questions. Anyone know how to read this stuff ? RED RIVER Cherokee Chat 16 03-24-2016 12:30 PM



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -5. The time now is 02:01 PM.