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Roof rack project

Old 09-08-2015, 08:48 PM
Thread Starter
Join Date: Aug 2013
Posts: 11
Model: Cherokee
Default Roof rack project

My son recently convinced me that I needed a Cherokee, and frankly my Mark VIII stinks in winter.. So I picked up a nice 2001 XJ. Once I sorted out a few things, like welding the spindles, new front brakes, along with other odds and ends it was time for the first project. So what else.. A roof rack.

Hit up the local new/used steel yard and came home with some 1" 14ga square tube and expanded steel sheets. Some quick sketches and measurements later I came up with the following.

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Whipped up some gutter mounts at work.

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Test fit.

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Old 09-08-2015, 08:56 PM
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Join Date: Aug 2013
Posts: 11
Model: Cherokee

Added some light tabs. Rolled on some Rustoleum, then overcoated with Rustoleum spray bedliner.

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Mounted up the lights. All light wiring is internal.

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Now just to finish up the harness and onto the something else.
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Old 09-08-2015, 10:36 PM
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JandDGreens's Avatar
Join Date: Jan 2013
Location: Colorado
Posts: 937
Year: 1991 2-Door
Model: Cherokee
Engine: 4.0 liter

That turned out pretty sweet, nice job!
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Old 09-10-2015, 06:59 PM
Thread Starter
Join Date: Aug 2013
Posts: 11
Model: Cherokee

Thanks! Not my first fab project by far. Nice to build something "simple" for a change.. lol

Last edited by SATURN5; 09-11-2015 at 09:06 AM.
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Old 09-11-2015, 06:00 AM
Junior Member
Join Date: Aug 2015
Location: SW MI Lake-effect snowbelt country
Posts: 55
Year: 1996
Model: Cherokee
Engine: 4.0 HO

how did you deburr the expanded metal? most of it I have seen has a lot of rough edges and I've cut myself working with it a number of times. I really like the look but personally would be concerned about what I'd put up there getting cut or scratched up.
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Old 09-11-2015, 06:08 AM
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Join Date: Jan 2010
Location: Oxford, CT.
Posts: 176
Year: 1998
Model: Cherokee
Engine: 4.0

Looks great.
love the lights.

Do you have a close up picture showing the mounting?

I'm not seeing where you actually bolted it to.
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Old 09-11-2015, 07:32 AM
Join Date: Oct 2014
Location: tucson
Posts: 17
Year: 1992
Model: Cherokee
Engine: 4.0

Looks good.
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Old 09-11-2015, 08:49 AM
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Join Date: Aug 2013
Posts: 11
Model: Cherokee

There is a stamped side and a burr side. I put the stamped side up.

Just a gutter mount. Some cut down angle iron.

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