Homemade Roof Rack without Welding
06-08-2011, 09:44 PM
#46
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Year: 1992
Model: Comanche
Engine: 4.0
Hmmmmm....Zack,go to a local JY and see if there is another 98 out there with a roof rail system on it. If so try and snag that, it will be the best for this type of rack I think. If not check out some of the roof rack sites and see what they have in gutter mounts. Im not real sure if they will work but its worth a shot.
Bear
Bear
Hey Zack, I had the same problem when I bought my 2000, had roof rails, but no cross members. I went to the junk yard and got the rails off of another xj, 99 i think. Then went to lowes and got 5x2x3/16 steel rails, cause I didn't like how flimsy the stock ones are and my rack is pretty heavy plus a 33 up there. Cut the steel to fit, drilled holes in my cross member sliders and bolted the steel pieces to them. Made them nice and tight so no rattle. Then used u-bolts and the flat piece of a box clamp to fasten the rack to the rails. So far no rattle and I've had my 33 on it, plus about 100 lbs of luggage and it doesn't even flex. I like it and it looks good. Don't have any pictures but I'll see if I can get some tonight. But like I said, I already had a roof rack that I built myself. If you just want the rails I would probably just stick to the JY pull offs. Just my opinion. 
06-17-2011, 10:58 AM
#49
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Year: 99
Model: Cherokee
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Great idea man...but it just seems like it would be very weak. I work with that stuff everyday and it kinks and bends easily. Also check the connectors often so they dont pull apart. The stock roof mounts are only supposed to hold 150 lbs. I had about 200 on mine and it was warping my roof. BUT if you are not going to have a whole lotta weight up there and your not worried about trees hitting it more power to ya. I love to see creative homebrew ideas. 
06-17-2011, 11:05 AM
#50
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Year: 1990 - 2000
Model: Cherokee
Engine: 4.0
Bend the conduit and save a dozen splices
Hi All,
First off, great job on the rack.
For those that want to reproduce this rack, you can save about a dozen of the couplers if you take 4 10 foot long sticks of conduit and use a bender to bend then into U shapes. I measured the sticks out and "borrowed" the bender in the local Lowes so that I ended up with 4 pieces that looked like: [________] Then I welded them in the center of front and rear of the rack with inserts inside. Splices would work here as well. It might be good to splice the bottom hoop on the sides and the top hoop in the front and rear. to offset the splices.
If you do not currently have any roof rack, you can search this forum for some good examples of gutter mounts.
Hope this helps.
First off, great job on the rack.
For those that want to reproduce this rack, you can save about a dozen of the couplers if you take 4 10 foot long sticks of conduit and use a bender to bend then into U shapes. I measured the sticks out and "borrowed" the bender in the local Lowes so that I ended up with 4 pieces that looked like: [________] Then I welded them in the center of front and rear of the rack with inserts inside. Splices would work here as well. It might be good to splice the bottom hoop on the sides and the top hoop in the front and rear. to offset the splices.
If you do not currently have any roof rack, you can search this forum for some good examples of gutter mounts.
Hope this helps.
07-06-2011, 07:41 PM
#52
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Year: 1989
Model: Cherokee
Engine: 4.0L I6
one thing about those couplers, come from the backside and set 2 self tappers( 1 on each side, just like the set screws) then remove the set screws and add 2 more selftappers. ( so that makes 4 screws per coupler) no more screws stickin out a half inch
no more screws stickin out a half inch
07-07-2011, 06:20 PM
#55
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Year: 1998 XJ
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I built a similar one about a year and a half ago. No screws have come loose. I haven't had any problems with mine. I used a pipe bender instead of buying pre bent 90's though. These racks are very strong. It would be even stronger using gutter mounts. Not really sure why most of the pics came out so small. Click on the link at the bottom to see bigger and more pics
https://www.cherokeeforum.com/member...g-7738/albums/
https://www.cherokeeforum.com/member...g-7738/albums/
09-30-2011, 11:01 PM
#57
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Originally Posted by Zacks98
So I just joined, (my first post! 
) So i just got my a 98 the other day, and it didnt come with anything on my roof..haha whatever you wanna call it, bike racks? I dont know... haha so how would you recomend me mounting this too my roof without just screwing it to the roof?
Oh and if you know of a write up of the top of your head,on how to wire up some light too that that would be greatly appreited! (haha im not sure if I spelled that right, but I see no red line so i guess so? haha)
Thanks in advance!
- Zack
) So i just got my a 98 the other day, and it didnt come with anything on my roof..haha whatever you wanna call it, bike racks? I dont know... haha so how would you recomend me mounting this too my roof without just screwing it to the roof?Oh and if you know of a write up of the top of your head,on how to wire up some light too that that would be greatly appreited! (haha im not sure if I spelled that right, but I see no red line so i guess so? haha)
Thanks in advance!
- Zack
10-03-2011, 12:17 PM
#59
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Year: 2000
Model: Cherokee
Engine: 4.0
I just finished mine up yesterday..
Mine was built the same way, without welding.
I used 3/4 & 1/2 EMT..... Seems solid so far, time will tell..
Here's a few pics
Mine was built the same way, without welding.
I used 3/4 & 1/2 EMT..... Seems solid so far, time will tell..
Here's a few pics
10-03-2011, 08:20 PM
#60
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Year: 1999
Model: Grand Cherokee
Engine: 4.7
Originally Posted by 4x4Dalton
Hey there yall. I made this 2 weeks ago figured I would share with yall. It took about 3-4 hours depending on yer speed and cost about 70-80 bucks to make. It has been on my XJ for 2 weeks now with Hi-Lift jack and a 31 and no give in it at all. I used 3/4 emt conduit to make this.
This size screw works best. Plus you need to get a Contractors box full of the 2 screw connectors to attach all this together
These are the plates that hold top and bottom 6 in high and almost 1/8th in. thick
Lucked up at Lowes they had it in 5ft sections. Need 6 total.
Bpught these 90% elbows cause I didnt have a bender.
One section done.
Once you attach one end with the 2 screw connector lay pipe down and maesure out to 52 in. lay elbow down and mark where it ends on pipe.
Halfway there.
Finished product but theres a lil more to do before mounting.
I primed it.
Painted it.Done.
Here it is mounted on the Grizzly. Grabbed hold of it gave a tug and whole Jeep moved its secure as hell.
Just another shot of the rack.
Hope yall like it. Its functional and weighs hardly anything,but doesnt give with tire on top of it. Thanks, Bear.
This size screw works best. Plus you need to get a Contractors box full of the 2 screw connectors to attach all this together
These are the plates that hold top and bottom 6 in high and almost 1/8th in. thick
Lucked up at Lowes they had it in 5ft sections. Need 6 total.
Bpught these 90% elbows cause I didnt have a bender.
One section done.
Once you attach one end with the 2 screw connector lay pipe down and maesure out to 52 in. lay elbow down and mark where it ends on pipe.
Halfway there.
Finished product but theres a lil more to do before mounting.
I primed it.
Painted it.Done.
Here it is mounted on the Grizzly. Grabbed hold of it gave a tug and whole Jeep moved its secure as hell.
Just another shot of the rack.
Hope yall like it. Its functional and weighs hardly anything,but doesnt give with tire on top of it. Thanks, Bear.