Another Roof Rack made from Harbor Freight ATV Racks - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 06-07-2012, 07:04 AM   #1 (permalink)
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Another Roof Rack made from Harbor Freight ATV Racks

For those who care about stuff like this.

I know Jscherb and USMCDOC14 have both made cargo racks for vehicles out of these parts previously. But hey, always room for one more, right?

I grabbed a pair of the ATV Cargo Racks from the HF in Omaha. 67623 is the part number. Then I grabbed 4 sections of 3/4" angle iron, 4 feet long. Also picked up 3 chunks of 3/4" square tubing, also 4 feet long.

I set the sections of the ATV racks on the roof of the truck I was working on and figured out that I wanted the finished rack to be 62 inches long. I had a long piece of 1" square tube in the shop, so I started with that as the 'spine' of the roof rack.

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Then, with it cut to length, I started clamping the ATV rack sections to the back bone.

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And then I plug welded the sections to the back bone, through the factory bolt holes.

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Of course, remove the powder coating where you will weld.
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Old 06-07-2012, 07:11 AM   #2 (permalink)
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I figured out that from the end of the rack, to the end of each section of angle iron I would have 7" (62" overall, minus 48" angle iron = 14" /2 = 7").

So I placed the angle iron as shown in the last photo above, at the top and bottom of both sides. Weld the ends, short welds in a few other locations.

Be very careful when welding to the HF rack tubes. They are like 26 guage. SRSLY.

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Then, take the 3/4" square tube and cut six pieces 23-5/8". Space them appropriately for the floor.

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Still needs cleaning, painting, and mounting tabs.

Hope it saves someone some time.

EDIT: And yes, this is a 'flux-core' project if there ever was one....
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Old 06-07-2012, 07:41 AM   #3 (permalink)
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That's pretty slick! Makes me want a roof to rack.

Any pics of it on your ride?
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Old 06-07-2012, 07:48 AM   #4 (permalink)
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Quote:
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That's pretty slick! Makes me want a roof to rack.

Any pics of it on your ride?
Will get pics this weekend when it is installed. Glad you like it.
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Old 06-07-2012, 09:30 AM   #5 (permalink)
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How much $$$ do you have into this? Great Job
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Old 06-07-2012, 10:02 AM   #6 (permalink)
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Quote:
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How much $$$ do you have into this? Great Job
The HF ATV racks are 39.99 each (32 on sale, sometimes, I think...)

So 80+tax at the HF store.

Plus 70 or 80 in steel.

So, 150/160 range. Definitely under 200 after it is painted and mounted.
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Old 06-07-2012, 10:30 AM   #7 (permalink)
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Do you have the dimensions of the stock HF rack? The website says 42x38 but it doesn't look like that is accurate.
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Old 06-07-2012, 10:49 AM   #8 (permalink)
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Quote:
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Do you have the dimensions of the stock HF rack? The website says 42x38 but it doesn't look like that is accurate.
I would almost guess that's the size of the box it's in.

I will get some overall dimensions for you, but just working off my memory...
The rack sections are 23-5/8" wide (I know that one, because I had to cut those tubes for the floor) and just over 19" long. The reason I guess 19"+ long is that I went with 62" overall length for this rack, and when I went to center the floor tubes, the middle one was supposed to be (iirc) 11-1/4" from either section, which means the gap between the sections would have been maybe 22-1/2".
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Old 06-11-2012, 07:15 AM   #9 (permalink)
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The assembly is 48-3/4" wide.

I made some simple tabs and bolted the basket to the factory roof rack rails. Removed the factory cross-bars first.

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I don't know why my phone occasionally re-sizes a picture and puts that damn border thing around it. But it does.
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Old 06-11-2012, 09:53 AM   #10 (permalink)
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Very nifty! I need to make one for my fj80.
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what's it like to own a buggy........i'd say it's like getting a blow job on a roller coaster
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Old 06-11-2012, 11:09 AM   #11 (permalink)
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Nice job! I have built a few roof racks for people, but I have never thought of using the ATV racks as a starting point. Well done.
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Old 06-11-2012, 01:40 PM   #12 (permalink)
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That's a creative use for those racks!
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Old 06-11-2012, 01:49 PM   #13 (permalink)
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Might have to go take a look at those racks. I've been trying to come up with a rack for my canoe that would mount on top of my truck camper.
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Old 06-11-2012, 03:40 PM   #14 (permalink)
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Thanks for sharing. You gave me some ideas for when I do my roof rack on the buggy
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