First Yota....Project Roof Rack (pic intensive)
 

First post here on Yotatech. I got my first yota, a 1988 4runner about two months ago. Since then I have been searching the forums non-stop for answers to questions and ideas for future mods. I have helped friends out many times design, fab and fix things for their off-road rigs and after many years of ho-humming finally bit the bullet.
I started by working out a few of the bugs such as the the blower motor not working on setting I and II which turned out to be the resistor. I also went through the entire rear window assembly after it started working only intermittently.
After looking through all my options, I have decided that I am going to go for an overland styled vehicle since this style fits the type of use I prefer. The first thing I did was order a small pile of steel and start fabbing up a roof rack.

I drew up a simple design to follow and can offer a PDF to anyone who wants a copy for their own use, just mail me and it's yours.

Here is a link to the original thread with the rail install idea that I used...thanks snwbrdr852
https://www.yotatech.com/forums/f116...nstall-197292/

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Let the cutting commence

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Time for the welder

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Now....time to accessorize! A highlift, shovel, and axe should do for now.
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Then there is the actual mounting of the rack to the truck. While searching a while before starting I had come across a post where the user had found some table saw set up rails that he mounted to his roof via rivet nuts. Having an automation background I ordered up some T-Nut channel and T-nuts, along with nut-inserts. This way, the rails would be mounted to the roof, which will allow me to possibly design other types of racks to mount to the roof in the future.

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The rails had to be machined to accept through holes and counter bores for the bolt heads. I do have a full machine shop (currently not wired in due to my recent move to the new house) so I used the drill press with mostly decent results (a bit of chatter from the 1/2" end mill is all).

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To mount the rails to the roof I drilled a boat load of holes for the nut inserts (11 per side for #10-24 nut inserts). Take time and make sure everything is where you want it...cause once you drill the fiberglass, its not easy to repair.

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http://i10.photobucket.com/albums/a1...ack/pic106.jpg

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Test fit
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Finally for mounting I drilled some 2" strap for 1/4" bolts and welded them to the underside of the roof rack structure. Gave it a quick shot of black paint which will later become powder coat. I intend on adding lights in the future and will weld mounting tabs to the rack, then it will be ready for the powder coating.

And the final result
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Thanks for checking it out. I will post build threads of all my major fab and modification projects as I get to them. Next in line, of which the steel is already in house for, are a set of sliders. I have a friend with a plasma table who is cutting some mounting plates for the frame...but more on that in the future.

awesome work! and welcome to YT :D

Nice rack. What was the cost for the mounting rails? Please pm me the plans if you don't mind

I'm bookmarking this! Great write-up man! My friend has a welding torch so as soon as I get the material I'll be starting this.

What size square tubing did you use? Looks like about 3/4"

Do want! :banger:

Rails were not cheap.....$100 shipped. Comes in 4meter section at $52. At 4Meters it would have to be shipped LTL (less than truckload) at around 100 bucks..yikes. But if you spend $1.95 and have it cut in half it can ship UPS at $20 bucks....whew. T nuts were .79 each.

Company is called 80/20

http://www.8020.net/
rails p/n: 40-2040
t-nut p/n: 40-3202

Yup 3/4" sq .063 wall for the hoops and vertical risers. 1/2" sq .063 wall for the basket cross supports. Cross supports are welded flush to the bottom, which creates a 1/4" lip for the 3/4-#13 expanded metal to rest in.

I will make a high res image file of the drawing and post a link here monday.

Here is the largest image of the drawing that photobucket will allow.

http://i10.photobucket.com/albums/a1...ROOFRACKII.jpg

great work man.. keep it coming.

Good looking rack. Thanks for 80/20 info. I can use that type if rail in some of my projects. Are the nut inserts water tight, or did you water proof them some how? Also did you use any backing mat'l. on the inside of the roof where the inserts crimp?

Nice work man!

looks great.. nice fab work too, should outlast the truck :)... did you add support between the underside of the top and your bolts?

wow very nice how much does it way

Nice work! That looks real nice. I like how low profile it ended up being with the mounting system. :great:

Nice build!!! Good job!!!

me likey! DANNNNNG, I need to reintroduce myself to some welding! BTW, if I begged, could I get those blueprints? lol.

Umm pretty sure he posted them so you could right click and save em. Lol!

Used some silicone around everything, doesnt rain much here in the desert, but when it does, it pours...so I guess we'll see.
I did not use backing, as the nut inserts are very short. I am a bit concerned about pull through, though i did some testing and they seem very stout, plus there are 22 of them all together. I know some friends who've used them on thier boats, after years they seem fine.


47 lbs for just the basket. Rails are about 12, and then the jack, axe and shovel i have no idea.

you should have enough support with that many, its not like your loading a quad or dirtbike up there... spare tire, some camping gear, fuel... ext.. is about the most it will see? maybe a lawn chair and a sixpack.. :)

HAHAHA, ....Kiyo, forgive me, lol. I don't think I'd really been on here, long, ....I checked out how it looked, scrolled to the bottom, posted, and didn't even know until about a month ago that I was subscribing to all these threads I visited! lol hahaha.

Anywhoooooooo, ....HOW MUCH FOR ONE FOR ME? hahaha. REALLY like that RACK, SIR! lol

It's cool chef. I am pretty much joking around 99.9% of the time. The .1%? Let's just call it the infamous "post 73"

hope you get your rig gets fixed, I have read your thread, and I have nothing intelligent to add to your search, so I decided not to send you on a mother wild goose chase. :D

Jerry (92Toy) was the one who told me about the who's online button. And it took me a long time to figure out the "last post" button by the last posters name instead of hitting last page and scrolling down everytime! :lof: