I haven't really ever attempted something like thins and I was wanting some guidance on what to do. I'm looking at useing my existing roof rack to mount it, also I was looking to use 1 in square tubing.

 

There was a write-up on pirate by Billa vista on a rack he built for his cherokee.
http://www.pirate4x4.com/tech/billavista/rack/

1" seems like overkill. I think it would have to be a fine line between building it beefy and building it overkill with too much weight up high. Good luck...I was going to do something similar but ended up buying a Yakima basketcase from rack attack.

Have fun!

 

thanks I appreciate it

 

I Have started to fab up a roof rack. I started with the four corners.Aplace to weld the basket to. I have finished two corners.When I make the last two I will digigraph the steps, and post here. What I have done was use the fasteners off of the stock roof rack. and will use the stock rail already attached to the roof.
I was thinking of 1" SQ Tube also. If you go with 1"x.065"wall tubing it weighs .8265 lbs per foot. so 40' would come to 33 LBS and should be enough to build the main structure I have already cut 12 3"x3" squares with a
2.5" hole in the center. These will be located 2 ea. per corner and one in the center of each leg of the basket. 1"SQ tube welded to the bottom and top of the 16GA hole in squares. This makes profile of the basket 5".The depth of the basket will be 4". The height of the roof rack mounts if I remember correctly are 2.5". That puts the finished profile of the basket 7.5" above the stock roof rack rails. If weight is still an issue you could reduce the weight by nearly half by using 1"x.035wall tube.
1"x.035 wall SQ Tube = .4533 LBS per foot.
I will try to get a few pix posted after I get home in the morning.

 

Thanks I appreciate that

 

Here are a few pix of those rack corners

 

here is a few more

 

some random drawing i did for an idea
once i learn to weld in the fall ill do this idea

 

Neliconcept... I think your idea has the doors welded shut.

I know, just conceptual. I found it amusing because I'd probably build a rack like that, mount it... and then realize I couldn't get in anymore.

 

yeah i realized that after I drew it, woops i guess im climbing through the windows

id prob mount the plates just above the door seals, or extend the tracks or something of that sort.