Outer Limits 4x4 Board

Gday guys. Anyone here fabricated their own roof racks before?
Im just about to buy a roof top tent and they want an extra $849 on ebay for a propper rack thats not even going to be the correct hieght.

Already priced up 25nb light pipe (black steel) and 25nb butweld elbows. All up the steel comes to just over $100.

Any hints, tips or pics?

Ive been toying with this idea lately aswell.. So would also appreciate any available info. One thing to check up on though is how much Powdercoating it will cost. I don't know about you but I don't want rust dripping all over my roof. The other thing I thought I would do was get the steel place to put the couple of necessary bend into a couple of pipes before I pick up the steel (a bit stronger that butweld bends)

I'm currently in the planning stage of doing something similar myself. A roof top basket. Tied into the 50x50x4mmSHS supports for my canopy.

I'm stuck on choosing the correct gauge of steel for the task.

Will be used frequently to cart the kayak (20kg).
And on road trips will be expected to carry approximately 120kg.
- Kayak (20kg).
- 2nd spare wheel (20kg).
- 2 x fuel jerry cans (40kg).
- 1 x water tank (22kg / litres).
- misc bits ie: firewood etc (20kg).

I was hoping to use 20x20x1.6mm SHS (have plenty on hand), but I doubt any amount of engineering will give it the strength to support the load over corrugations.

Now I'm thinking 25x25x2mm SHS. Does this sound up to the task or would I be better looking at 32nb pipe or similar?

probably the strongest and cheapest way is to get 3x rhino racks and use this as your base to bolt a tradesmans rack to .these are on ebay most weeks and no one chases them.you wont build a clamping system as good as the rhino for the money.

I made a roof rack about 6 yrs ago using 25x25x 1.6mm, I have a roof top tent and all recovery gear, roof awning and rod tube hanging off side. This rack has done the simpson a couple of times, the canning and the cape, it is as strong as, has no cracking and will still be going when the 4by has probably died. I was toying with getting it powdercoated but after seeing the mess the bullbar became decided on galvinising instead, looked very silver until it weathered but has settled down now.

GaryP wrote:I made a roof rack about 6 yrs ago using 25x25x 1.6mm, I have a roof top tent and all recovery gear, roof awning and rod tube hanging off side. This rack has done the simpson a couple of times, the canning and the cape, it is as strong as, has no cracking and will still be going when the 4by has probably died. I was toying with getting it powdercoated but after seeing the mess the bullbar became decided on galvinising instead, looked very silver until it weathered but has settled down now.

Can you hit us with a foto......

Too late, Ive already made it. Total cost in materials is $135 25nb light pipe, 25nb long radius elbows, flat plate, 65 x35 rhs, 25 shs, cutting wheels, flapper. All welded up with my $500 special mig. Looks awsome and very proffessional. I am 3/4 finished and havent taken any photos of my build yet. But I will and give dimensions for those who want to copy.

Very easy to do.

I may be getting them powder coated for free, but not sure yet.

Will post everything soon.

Just made a basket for a mate yesterday out of 25 dia x 3 ally tube for the frame work 50x6 flat bar to hold the top loop on and security mesh for the floor. Weighed about 15 or so kgs and was solid as. As said before mate brought rhino racks and then bolted the basket to it. $170 for materials and a light weight strong basket on his roof.

Ok. This is turning into something now. There has been HEAPS of interest with this build. So im going to start a new thread for people searching the net trying to find Roof Top Tent Roof Racks.