Modified a 3rd Gen 4 runner roof rack onto my extended cab, figured I'd post pictures and how I did it. It's super solid, I can hang all my 215 lbs off of one corner and the roof doesn't flex.

Took a roof rack and cross bars off 3rd gen 4 runner, cut them down and mocked them up. Drilled a couple holes in the tracks to keep them held down since the back section is so short.


Used rivnuts, which is the way the factory had it installed in the donor 4 runner

Painted the cut down tracks, and mounted them with ample amounts of sealant to keep it water tight.




Did this for preparation for what I'm making now, a roof basket. Still working on it. made of 1" and 3/4" conduit, its pretty solid but still light weight.




Should look like this when its done, but I'll have a plexiglass fairing and will be putting a lightbar and a couple spotlights behind it.
http://www.cherokeeforum.com/attachm...0516112247.jpg

 

Got the basket done except for the mounts to the tracks and the finish welding and paint. And the fairing

 

Sick dude, you did a killer job mounting that rack and fabricating the basket. Only thing I would suggest is trying to get the basket mounted a little lower.

Otherwise, damn good work and you should be proud of that.

 

Thanks, it was just sitting up on the cross bars for the picture, I plan to have it sit about an inch lower and mount to the tracks. The cross bars themselves aren't that stout but the tracks are. I'm also going to make a mount for my spare up there so I don't have to strap it down.

 

Great job and write up. It looks like it came that way and with the end caps on it, helps to give it that finishing touch.

 

Finished up the rack for now. When I get my light bar and spotlights down the road i'll fab up my mounts for them behind the fairing, so for now I just spray painted it . When its all done with the light mounts i'll smooth out the welds some more and might get it powdercoated, or at least sandblasted. The fairing is clear acrylic, with a sticker on it. The lightbar will go behind it once I get it. The mounts have 2 tubular uprights on each corner welded to a piece of flat plate that sits on top of the track. Used the stock 4runner hold downs to hold the the basket, just had to get some more hold downs. 6mm bolts would work as well.

I'll get pictures of the mounts later today as well as pictures of it mounted.

 

That thing is sweet keep up the good work

 

Got it mounted up. Need to either space the factory hold downs up off the mounts or use some shorter stainless bolts. Also need to throw another coat of paint on it. But i'll let it cure for another couple days first. With the fairing there isn't any more audible wind noise than before.

 

gyaaaaaah.
I HATE you fab guys! haha
so jealous. I'm still trying to learn how to solder!

 

I just finished building this one for my truck. It's actually the second one I've built for it, this one is just bigger and much nicer than the first as I could take my time, integrate features I wanted and not be in a hurry to use it. Plus I had better tools, which always helps. I added 3rd Gen 4runner tracks to the roof, sectioned as the roof of my truck raises up in the back due to the extended cab part. The lower hoop and cross bars are made from 1" EMT Conduit, and the upper hoop is 3/4" EMT conduit. The plates that support the upper hoop and separate it are 1/8th thick. Integrated in some lockable shovel and axe mounts on the passenger side, and making a simple bolt through style mount for a high lift on the drivers side, although it usually rides in the bed of the truck. Also made a moveable tire mount that clamps to the crossbars using stainless 5/16 thread u bolts from McMaster. The top plate centers thru 4 of the lug holes of the wheel, and the bolt is 7/8" diameter grade 8 bolt and nut. It shouldn't move or break. The hoops were bent with conduit benders so there are only 2 weld seems per hoop, which are sleeved for strength. Also made mounts for a 42" Led light bar up front and twin rear facing 27w LED lights that I had on my old rack. The goal for this rack was to be big enough to carry a full size 35" spare (eventually, some day) or my current size spare (32") and a cooler. Mounts are 1.25" flat bar that run the length of the track, with 4 bolts on each front pad and 3 on each rear pad. Will be getting powdercoated to match the bumpers.