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Home made low pro roof rack

Old 12-13-2014, 10:43 AM
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Default Home made low pro roof rack

Hello, I figured Id share my roof rack I completed a couple weeks ago. I made my own rack 2 winters ago out of square stock, but it ended up being way too heavy and too bulky. I was proud of it at the time but I knew I could do better. I started his rack about 2 months ago and worked on it when I had a chance after work (my boss let me keep it in the shop and I used his welder).

Here is the old rack I made. I used JCR's gutter mounts to attach to my XJ:

















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Old 12-13-2014, 10:50 AM
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As you can see that old rack is ok for some things, but I needed more of a low profile and less weight, plus I plan on getting a Roof Top Tent in the future so I needed it to work with that.

I decided on using 1 1/4 120 wall tube steel. My boss and I are friends with many of the local business owners and he hooked me up with a guy that bent my 90's while we unloaded a bit of firewood from his pickup. I thought that was a pretty good trade! I was so excited to get started on this new rack that I forgot to take more pics... so hopefully the ones I do have will make due.
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Old 12-13-2014, 10:59 AM
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Heres where I started taking pics. This is after I welded all my 90's together. I used 1" tubing about 8 inches long where each section met, it fit perfectly inside my inch and quarter tubing and made it nice and sturdy.








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Old 12-13-2014, 11:25 AM
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I added 1" trailer gate mesh on the back section, I wanted it to be a little bit more "open" because I knew of I had a tire up there it'd be easier to clean off if the rack got too muddy. I finished the rest of the rack (front section) off with smaller diamond flat mesh which was smaller and also very smooth.

Here I was test fitting everything




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Old 12-13-2014, 11:48 AM
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I ended up coating it with Rustoleum primer then adding a few coats of Dupli-Color Truck Bed Coating over that. Finished it off with my LED lights (and 2 halogens) and Im very pleased!







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Old 12-13-2014, 12:04 PM
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Both racks look great! One day I'll tackle one. I like the Camel Trophy style myself, but I can see a lot of advantages of your new lo-pro one. Great job!
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Old 12-13-2014, 12:14 PM
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Originally Posted by JeepTrick68 View Post
Both racks look great! One day I'll tackle one. I like the Camel Trophy style myself, but I can see a lot of advantages of your new lo-pro one. Great job!
Thanks. I still have the old rack, well half of it at least. I chopped the top half off of it and flipped it around to make it smaller. Its on my younger brothers XJ now. I really liked the Gobi stealth rack and thats what I was originally going to do with mine but last minute decided to keep it even more simple.
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Old 12-14-2014, 05:01 AM
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so you used 1" round stock, correct? Were you able to find that locally or did you order it? Can I ask what your total cost was?
Looks great by the way!

Last edited by jw13; 12-14-2014 at 05:02 AM. Reason: added comment
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Old 12-14-2014, 08:57 AM
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Originally Posted by jw13 View Post
so you used 1" round stock, correct? Were you able to find that locally or did you order it? Can I ask what your total cost was?
Looks great by the way!
Hey thanks!

I used 1.25" x .120 wall tubing round stock. I used 1" to connect the sections together, basically I had two "staple" shapes that were 1.25" joined to make a rectangle, where they joined I cut an 8" piece of 1 inch and slid it inside the 1.25" as a stiffener (4 inches to each section). Any of the flat stock you see is all .120 wall. I put those pieces in for future mounting points (tire, jack, etc.).

I ordered my steel locally and had maybe $100 roughly in steel used, plus $40 for the JCR gutter mounts. Add welding wire and paint it was all built for less than $200. Overall dimensions were 48" wide x 72" long.
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Old 12-15-2014, 06:20 AM
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nice work
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Old 12-15-2014, 11:12 AM
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Love it
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Old 12-15-2014, 11:35 AM
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some nice work there
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Old 12-15-2014, 11:54 AM
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Thanks for the inspiration. I bought 48' of the square tubing like yours, but hadn't decided on a design. It was going to be more simple, but I like your first one so much, I'm going to go that route.
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Old 12-15-2014, 02:59 PM
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Looks great! I'm going to be building a low pro roof rack as well at some point.
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Old 12-15-2014, 03:28 PM
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Nice. JCR mounts probably cost more than everything else combined.
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