Another low profile roof rack build

Well now that I have finally finished some side projects and more importantly my front bumper I can get started on my roof rack. Like many others I'll be taking some inspiration from a few racks that are currently in production and from a few guys on here who have also decided to do the same. I'll be using .25" plate aluminum which should be more than enough to make for a strong rack. Now for the fun part of getting all the curves measured so that this will sit low to the roofline and not look like crap. Shout out to @ORNG TACO for answering some questions in his thread about how he went about doing a few things.

 

I'm working on a similar project. i have an existing pipe rack that I'm trying to work around. the rack is largely to mount a deflector. the pipe rack creates a bit of wind noise after 40mph. didn't want a deflector mounted to the pipe rack so going the route of a mini cab rack. while I'm at it I'll be throwing on some lights.

are you going to try keep the side pieces straight or follow the weatherstripping and be wider in the front? cross pieces welded or bolted? going with a flat fairing in front or rounded like meso's?

 

The side pieces will be straight. The cross pieces will be bolted in place using aluminum extruded bars from 8020.net. and I'll be using a flat fairing that matches the curve of the windshield.

 

So after taping some cardboard and rough cutting it to the curve of the roofline, I then used my handy sharpie to trace the curve then taped the cardboard to my dining room table and marked out a straight line and the wind deflector angle and back of the cab departure angle. Marked out every .5 inches and used that to measure from the straight line down to the curve so I can use that to input this into fusion 360.

 

Well this is what I have come up with so far. Still need to make some test pieces and check the fit. Not sure how the TRD logo Is gonna work out though. It's kinda thin in a few spots.

 

Staying tuned, awesome rendering

 

Your width is off. The "Toyota Racing Development" should go edge to edge of the "TRD". Making it a little wider should help with the thin parts a bit.

 

Watching this one

@LivinLoud

 

For metal integrity purposes shouldn’t the logo be centered vertically with even spacing above and below in this pic?

 

I support it! Looks great to me

 

@s7726 I do agree that it needs some fine tuning in terms of ascetics. The part im worried about is that the R is about .02" thick between the curve and the vertical portion of it. im hoping to make some test pieces tomorrow to be able to see it full size.

 

I should also add that I didn't make the TRD logo. I found it online on Grabcad. so that was a huge win.

 

https://youtu.be/Pjep8oKTqzE

 

@caribe makaira I wish I could have used something like that. Hard to find one 65" long to do the whole roofline

 

Build it..., You could even place a L bracket where the bolts go for a sure fixture placement as you get the contour.

 

Well I think my test piece came out pretty good. Used our laser engraver to make a test piece to check the fit as close as I can right now. Have to say it came out pretty clean and all the roofline mounting holes lined up which is surprising. I figured at least one would be off. I still need to add the mounting holes for my quick fist mounts and clean up anfew things like the TRD logo.

 

Not a bad idea. I'll have to keep that in mind.

 

that's pretty sweet! great job. can't wait to see the final result

 

@S5sTacoma Thanks man. Im hoping in the next few weeks I can get all the parts ordered and then start assembly. I still need to mill out my spacer blocks for in the drip rails.

 

well its been a while. I got another rack designed for my brothers Lexus GX470 and finally got them both rendered to see if there were any issues in the design before cutting. found one or two and got them fixed. here are a few pics from fusion 360 of mine.