Custom roof rack build!

[Mykdee]

I have wanted a roof rack for awhile now and I do not like the options out there. I personally think 1" tubing is way too small for a Expedition. So I decided to build a 1.5" roof rack, it will be 90" x 44" with custom plate mount that use the existing factory roof rack holes. It with be mostly a platform in the rear that I can mount a RTT and the front will have double tubing to use for storage.
I will post pics as it comes along.

 

[Dennis_H]

One thing to remember is that those internal nuts in the roof are just in the sheet metal roof, not in any braces. They will rip out. (unfortunately I know...)

 

[HawkX66]

One thing to remember is that those internal nuts in the roof are just in the sheet metal roof, not in any braces. They will rip out. (unfortunately I know...)

Good to know. Thanks. I was thinking about doing the same thing.

 

[ExplorerTom]

You could drop the headliner and put larger bolts with big washers to keep them from pulling through.

 

[Flexpedition]

One thing to remember is that those internal nuts in the roof are just in the sheet metal roof, not in any braces. They will rip out. (unfortunately I know...)

I'm surprised to read this.



So instead of the roof rack mounting on the "side rails" (#4 shown) or the "cross rails" (#3 shown), or ideally where these two components join, you are saying the rack mounts 100% to the roof skin itself, panel #1?

 

[Dennis_H]

At least the front one, and the rest look the same. Had a kayak on J-hooks up there on the OEM crossbars. Not sure why or how, but the front of the sidebar on the drivers side ripped out of the roof and did bad things. I bought a used roof rack from the wrecking yard and made a new forward mount point with a large fender washer with a jb welded nut on it. There was no brace anywhere near that hole. I have a kayak trailer now.

 

[Mykdee]

This is what I have done so far, gives you a rough idea of the design I am trying to accomplish. Still have a lot to do, need to make the brackets and weld up the upper bar that goes up front. The brackets will be about 12" front and rear and a 6" bracket in the middle. They will actually mount to where the roof seam is like in the picture. I really like the look of the larger diameter tubing for the roof rack, no question about it 1" would of looked tiny!!

 

[Mykdee]

Next....I need to build a side ladder to access the roof rack AND a rear bumper with a tire carrier!

 

[Mykdee]

Made a lot of progress this weekend.

 

[Mykdee]

Got it mounted, not sure if I should of went lower with the top hoop?!