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Homemade Roof Rack With 4 KC Lights

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Old 06-12-2011, 10:26 PM   #1
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Default Homemade Roof Rack With 4 KC Lights

Homemade roof rack built and installed on the factory roof rack mounts. Built out of thin wall square tubing and some other types of metal...

Feel free to ask questions and complete plans can be posted......

Homemade Roof Rack With 4 KC Lights-img_20110510_170404.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_170411.jpg

This is the first start to the rack..... cutting stages
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Old 06-12-2011, 10:29 PM   #2
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Homemade Roof Rack With 4 KC Lights-img_20110510_173631.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_173638.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_175950.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_175958.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_180006.jpg

These are the first starts to every piece of metal cut....
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Old 06-12-2011, 10:32 PM   #3
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Homemade Roof Rack With 4 KC Lights-img_20110510_181214.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_181222.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_181228.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_181536.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_181543.jpg

Mockup of all fitting metal..
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Old 06-12-2011, 10:36 PM   #4
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Homemade Roof Rack With 4 KC Lights-img_20110510_183205.jpg

Homemade Roof Rack With 4 KC Lights-img_20110510_183218.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_115831.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_115849.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_120525.jpg

Welding of the bottom assembly, and finish grinding....
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Old 06-12-2011, 10:38 PM   #5
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Homemade Roof Rack With 4 KC Lights-img_20110514_120611.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_120855.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_120901.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_124921.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_125306.jpg

Final bottom assembly....
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Old 06-12-2011, 10:42 PM   #6
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Homemade Roof Rack With 4 KC Lights-img_20110514_132208.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_132214.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_141337.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_141343.jpg

Homemade Roof Rack With 4 KC Lights-img_20110514_141410.jpg

starting of the top assembly....
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Old 06-12-2011, 10:46 PM   #7
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Homemade Roof Rack With 4 KC Lights-img_20110514_142209.jpg

Homemade Roof Rack With 4 KC Lights-img_20110515_142347.jpg

Homemade Roof Rack With 4 KC Lights-img_20110515_144911.jpg

Homemade Roof Rack With 4 KC Lights-img_20110515_153613.jpg

Homemade Roof Rack With 4 KC Lights-img_20110515_153623.jpg

Final top and bottom assembly welded and finish grinding complete
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Old 06-12-2011, 10:50 PM   #8
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Homemade Roof Rack With 4 KC Lights-img_20110515_153637.jpg

Homemade Roof Rack With 4 KC Lights-img_20110516_194217.jpg

Homemade Roof Rack With 4 KC Lights-img_20110516_194248.jpg

Homemade Roof Rack With 4 KC Lights-img_20110516_194317.jpg

Homemade Roof Rack With 4 KC Lights-img_20110516_194342.jpg

Complete top and bottom assemblys and angled pieces....
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Old 06-12-2011, 10:53 PM   #9
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Homemade Roof Rack With 4 KC Lights-img_20110526_174701.jpg

Homemade Roof Rack With 4 KC Lights-img_20110526_174822.jpg

Homemade Roof Rack With 4 KC Lights-img_20110529_142700.jpg

Homemade Roof Rack With 4 KC Lights-img_20110529_142715.jpg

Homemade Roof Rack With 4 KC Lights-img_20110604_144754.jpg

Mounting assembly and rack assembly welded and finish grinded....
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Old 06-12-2011, 10:57 PM   #10
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Homemade Roof Rack With 4 KC Lights-img_20110604_144903.jpg

Homemade Roof Rack With 4 KC Lights-img_20110604_144913.jpg

Homemade Roof Rack With 4 KC Lights-img_20110604_144930.jpg

Homemade Roof Rack With 4 KC Lights-img_20110604_144952.jpg

Homemade Roof Rack With 4 KC Lights-img_20110604_145007.jpg

Completed rack and mount, welded and grinded light and tire mounts....
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Old 06-12-2011, 10:58 PM   #11
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Homemade Roof Rack With 4 KC Lights-img_20110604_145020.jpg
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Old 06-12-2011, 11:02 PM   #12
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Homemade Roof Rack With 4 KC Lights-img_20110605_133146.jpg

Homemade Roof Rack With 4 KC Lights-img_20110605_153922.jpg

Homemade Roof Rack With 4 KC Lights-img_20110605_153950.jpg

Homemade Roof Rack With 4 KC Lights-img_20110605_154011.jpg

Homemade Roof Rack With 4 KC Lights-img_20110605_154025.jpg

Completed primed and painted black.....
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Old 06-12-2011, 11:05 PM   #13
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Homemade Roof Rack With 4 KC Lights-img_20110606_200334.jpg

Homemade Roof Rack With 4 KC Lights-img_20110606_200358.jpg

Homemade Roof Rack With 4 KC Lights-img_20110606_200406.jpg

Installed without lights....

Please give any suggestions on who to hide wires for lights and other accessories.....
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Old 06-12-2011, 11:05 PM   #14
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How much tubing did you use? or have you used? size ?
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Old 06-12-2011, 11:11 PM   #15
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I used 3 sticks of 1inch square thin walled tubbing (20 feet long) and still had some extra left over...

Benco steel gave me the best prices...

The light mounts and tire are made of 2inch wide .25 inch plate, and the tire mount (not completely finished) is made of 6inch wide .25 plate...
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