Help with roof rack build
 

I've been admiring the many roof racks you guys have built and posted on here and I figure it's time I give it a try. I have a nice welder and the stock roof rails on my xj to mount it on. Would galvanized steel be way too heavy? Is aluminum too hard to weld? Just a basic idea of where to start with these things would be really helpful. I don't want a masterpiece. I just want to have a good time with the build and hopefully make one I can use. Thanks for the help.

Aluminum has to be heliarced, galvanized gives off gas when welded that can make you very very sick. If you have to use pipe instead of tubing. Use black iron pipe, but heavy compared to tubing. Do a goggle search, somewhere in your area should be a metal supply. Just built mine, 3/4" 16ga. square tube. With tubing, all the consumables and paint about $70.

That's a huge help. Thanks.

i got my material at home depot 1" square tubing and it is pretty light but can handle a lot of weight

That sounds great. What are those clips you used to secure it to the rail on the roof?

I'm hoping my highway gas mileage won't go down too much if I use diamond plating or something similar slanted in front. Is this wishful thinking?

Yes your mpgs will go down. check out my pics mine has three pieces of 16gage plate on the front. Havn't had it on long enough to get good numbers on the mpg

you mpg may only go down a mile or 2, shouldnt be that much if you have a slanted "air dam". however it does create an airfoil in the rack itself.. kinda like the tailgate theory on a pick up truck.

I copied Warthogs with a couple mods. I built mine out of 3/4" emt for the main loops and 1/2" for the cross bars. It's bolted together (I live in an apartment, so welding was'nt an option) it's stout as hell, I kept reading posts about this method leading to a squeaky rack, I disagree, I don't even know its up there. Total cost was $90, the self etching primer and the bedliner I finished it with cost as much as the materials. Good luck on your build and be sure to post up some pics when its done.:cheers:

Very nice. Looks great with the metal screws.. I still think I'm gonna weld though- the drilling process would probably just as lengthy. I'll be sure to post pics! Thanks everybody for the help.

slef tapping screws do the drilling for you

just make sure you use a square to keep it symmetrical. remember the old saying measure twice cut once. also during the build process, it's a good time to make any mounts or accessories you may end up wanting.

Very true. I think I'm just looking for a reason to get out the welder.

I know I would regret not welding in a tire mount. I'm been thinking lazily and planning on strapping it in. I should probably just do it right.