Custom Roof Rack Mounts

[Matt]

I was talking to one of my buddies who works at a machine shop and he said it really wouldn't be too much trouble to get some CNC machine time, especially since I can do all of the design and just transfer the model file to the machine to do the work.

So..... I'm simplifying it for the time being. I'm going to make the basic style clamp mount (shown below). I'm also going to use a square u-bolt with tri-groove nuts on top to make it a bit more theft "resistant". This isn't shown in the model....





Then, once i have my roof rack on I can take my time and really make some cool mounts for it to eliminate the crossbars.

[Matt]

Materials here. Debating whether or not to downsize the U-bolt size.... But I like the 3/8-16 thread and tri-groove nut size. We'll see how the first test piece comes out...

[Matt]

Got the rest of the material... 1.5" bars. 1/8" thick for the top clamp and 3/16" thick for the lower clamp. Also got 70A durometer fiberglass reinforced silicone rubber for the lower clamp (the red stuff) and 60A durometer EPDM rubber for the interface between the stanchions and the stock roof rails. Both rubber strips are 2" wide, 1/16" thick and have an adhesive backing.



Plan on getting to work tomorrow.... i'd like to have my cross bars mounted up by Saturday afternoon. Hopefully our 2" cutter comes in for the mill tomorrow!!

[cico7]

matt, where did you find your U bolts and tri groove nuts? is that something fasten-all would carry?
there is a fasten-all place not far from me.

[Matt]

Yeah, fastenall would have them. I ordered from mcmaster

[Matt]

Just made the lower clamp prototype... worked like a charm!

[pjmjr508]

I really like the mout so far

[Matt]

Thanks!!

Done working for the night... just put my son to bed so I can't use the compressor/grinder. I have 3 of the lower clamps sprayed with primer and the other 3 are still in "manufacturing" (just need to cut the notches and clean up the edges, then primer).

I think I'm just going to do everything, including the stanchions, in white primer and see how it looks. Since i'm doing 6 mounts i'll be able to take 2 off at a time and paint them black if I want.

[CmmdrDan]

Looks good. If these come out well would you be interested in make more? Ill pay..

[Matt]

That sure wouldn't be out of the question....
Lets see how the machining goes tomorrow. Those lower clamps took me a lot longer to make than expected and I broke some drill bits when they caught (and smashed my ribs), but they'd be easier to drill if i was over my friends using his drill press; but im just too inpatient.