Custom Roof Rack Mounts

[Doc in AZ]

Dude, you have to get away from square stuff. I make roof racks from round tube for a reason... drag coefficient. Make it a little smoother, trust me, you will see a Los in MPG try to minimize it... and make it appealing not just functional. And roof racks come in any size you want and even in irregular shapes.

http://www.facebook.com/media/set/?s...5811010&type=1

[Matt]

Doc, its all squared off for concept only. Once I chose a design I will then modify it for aerodynamics and aesthetics. There's no point in spending another 20-30 minutes on each model to make it look pretty.

Edit: and what do you think about the welded bracket idea? I was actually thinking that if I had you make those brackets then I could even forego making tall stanchions since the brackets would just need to extend about 3/4" below the bottom of the rack. Then I'd just machine some platforms out of steel to give the rack a level surface instead of the angled rail. Ill draw that up tonight after my bike ride.

[CmmdrDan]

Ok back to the task at hand.... Good chance I'll still have to use my Thule load bars for the time being (although I love the direct mount idea). Here's another concept that i like for a few reasons:
1) Doubles the mounting bolts = stronger and a lot more work to remove
2) Wider foot print for the mounts
3) Don't need to drill hole through load bar = easier adjustments

Downside is about double the cost (due to material scrap mostly... can order in 1' or 3' sections and only need a 20" section to make 6 mounts). But then again i'm sure I'll have a few prototype pieces anyway... so even if i go with the 2" mounts I'll probably want to get the 3' material regardless for mistakes and modifications to the design.

I dont think I'd do it this way. Would want a bolt through the rail so it doesn't slide back and forth. Unless you put a small weld or something.

[Matt]

Dan, it wouldn't be able to slide back and forth. Every Thule setup you can buy uses clamping force to retain the bars.... and I can far exceed the clamp force of every Thule mount I've used with the 2 3/8" bolts, so I'm positive there's enough there to hold it in place.

[pjmjr508]

Since you have the same rack I have been watching this thread intently, depending on how much of the cost (& if you want to as well) I would have you make a set for me. Also I will say this, doing 3 bars for support is a great idea.

[Matt]

From setup to cleanup its about 10-12 hours of work to make a set. Material for a set of 6 costs between $50-60 after tax and shipping. I'm a busy guy with 2 kids at home and a lot of other projects/hobbies. So, although I would be happy to make a set for you, I'm not sure if they're worth as much to you as a full day of work is to me. If I could knock them out in 1-2 hours total it'd be a no brainer, I'd probably ask for $150 for a set of 6 (that's about $70 profit after material and shipping them) and knock them out one morning before lunch. But being that if I start at 9am and wont finish till the evening.... hell even if I only ask for $30/HR that puts it at a good $350/set which I doubt anyone is willing to spend.

If enough people want a set I can try getting a quote from a local machine shop (they'd knock them out a lot quicker on a CNC). Although I'd guess it'd still be $200-$300 for a set, at least they'll be precision machined (so more bang for your buck ).

[pjmjr508]

I fully understand and agree. With it taking so much of your time, it is not fessable.

[Matt]

Lol it got to the point after I made the first 2 (not complete though) where I almost just scrapped the idea. That's when I modified the design to eliminate the milled channel for the bar to sit in just to make it worth finishing.

[pjmjr508]

LOL