rabblerouser

Built mine a while ago, just recently added the lights and light bar to it. my aging luggage rails are not likeing the weight with the spare up there, so im going to have to do something to beef up the mounting system.

5ftx4ftx6" all 3/4" EMT, couplings, self tappers, and 6" decking corner braces.
Total build cost for all the hardware and material, 90 bucks, and 5-6 hrs worth of work.

XJ Jake

It's Krylon Satin Italian Olive.. It took 8 cans to spray the whole truck.

94 jeep md

This thread is just full of ideas, now all i have to do is get up off my rear and get to work.

The great thing about EMT is it is on almost all the jobsites i work at.

TbachXJ

How did u attach it to the stock luggage rack ?

rabblerouser

I used 8 1" pipe ubolts w/lock washers to bolt it to the stock luggage rack. Mocked it up with the bolts, got them as tight as i could with a wrench on the roof, then pulled the rack off by removing the luggage bars, and cranked em down the rest of the way w/ a socket wrench, and used an angle grinder to trim the excess threads off so they dont tap the roof over bumps.

cherokee_ftw_5

my idea is ditch the stock bars, drill holes in the conduit, and run a bolt through the conduit and into the threaded plate where the original rack bolts to, so that it keeps it lower profile, and it's not on arched bars so it can bounce, and it's still movable forward and back. I'll take pictures when I do it.

DertiBerti

This is how i did it

mattphillips90

When you screwed it down onto the roof rack, did you use longer sheet metal screws to go all the way through the pipe into the rack or did you drill a top hole for the screw to go through?

xj guy

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coloradoboy

so here is how mine is built, i cut the pipe ends in half and then flattened them, then secured them with self tap screws

JerrytheJeep

Would those bend at all? That sounds like a good idea I was just wondering if they would want to buckle under any weight.

coloradoboy

not so far, i have been standing on the rack with the tire and my hi-jack on it as well, and it has held up really well

Guttrshark

Great idea. Im glad i stumbled on this. I dont have a welder or much experience welding so this might be what i do when i get around to a roof rack.

Just a thought for people worrying about the stock roof rack cross members..

I was just thinking that you could get more cross members to to distribute the weight better over the stock rack, especially if you have a tire up there you that would help lessen the strain put on the cross members...

just an idea!

xj_jeep1

emt is easy stuff, looks good

JAYSSICKXJ

Do u have a pic of your hi lift jack mount?