StuRox

Well-Known Member

• Jan 29, 2016

• #1

Have also posted this in the wanted section, but also here, given my idea might be of use to someone else...

Just wondering if anyone has any old Roof Rails lying around off a D1 that they don't want, as looking at an idea of making a separate set of rails to extend the ones I have to make a full length version, so ideally I need two sets to weld them together in a mad scientist way to bolt onto the roof!

Idea is something like this.....

and then I can use the bars across and remove them like the front ones.

Am based near Bath/Bristol if anyone is local I can pick up....

I have normally made the full expedition racks in the past, but reckon this will save a hell of a lot of metal and weight, and also look semi factory fit??

What you guys think?

Cheers

 

Discokids

Well-Known Member

• Jan 29, 2016

• #2

I've seen these before, I think they were available as an optional extra weren't they?

 

StuRox

Well-Known Member

• Jan 29, 2016

• #3

you can get the extending bars, but they were only for the D2 from what I have found out, plus they seem to go for silly money when they pop up on ebay.

much better fabricating something for yourself

 

KNine

Active Member

• Jan 29, 2016

• #4

I don't use my bars that go across so you are welcome to have them, but I don't have spare rails.

 

StuRox

Well-Known Member

• Jan 29, 2016

• #5

Ok thanks for the offer.

I think i will be sorted come tomorrow and will let you know.

 

StuRox

Well-Known Member

• Jan 30, 2016

• #6

Well, the plan is now a goer, thanks to fellow member Saltlick for the parts

Have now got everything I need to start on this idea.....

Now I just need to find the time.....

 

StuRox

Well-Known Member

• Feb 1, 2016

• #7

or a day without rain!

 

StuRox

Well-Known Member

• Feb 3, 2016

• #8

My 30mm hole cutter landed today for making the holes in the roof to allow the bars to sit properly.

Hoping the weather will stay dry at the weekend and if so will have a go at fabricating them up.

 

StuRox

Well-Known Member

• Feb 7, 2016

• #9

First day without rain so thought i would make a start.....which didn't go too well....

Rails are aluminum which i cannot weld.

Have got another idea up my sleave...just got to get more supplies before i can start mk2 version.

 

Saltlick

Well-Known Member

• Feb 11, 2016

• #10

Bugger! What about durafix EZWeld rods for the ally? They're very good and bleedin strong...

 

StuRox

Well-Known Member

• Feb 11, 2016

• #11

I do have a work around idea, just need to find the time to get to my local steel supplier and see if will work.....but thanks for the heads up on the EZweld rods

 

StuRox

Well-Known Member

• Feb 11, 2016

• #12

I have now got the steel I was after in the hope I can make new rails over the aluminium ones to try and keep the standard look and still use the mountings.

Will hopefully get a chance to do a bit of cutting and welding at the weekend.

 

StuRox

Well-Known Member

• Feb 13, 2016

• #13

Have now made some progress, as crappy rain so have managed to get some time in the garage.

I started with some 3mm box steel...

then made up a little sample to see if it would work, and fitted nicely over the bar...

So with that working, made up a full length bar, cut out the bottom, bashed it together, welded and grinded it down...

and then painted...

just need it to dry and then I can drill in the mounting holes for the crossbars and then put them on the roof

Once on the roof I will seal up the gaps with the sealer that I use to stop the roof leaking to make it look more of a professional look

 

StuRox

Well-Known Member

• Feb 15, 2016

• #14

All done and fitted

Not too bad considering the price it cost me (cheers Saltlick ).

A lot lighter than the full expedition racks that I have made and fitted in the past.

Would have preferred if I could just have welded the bars together and not needed the box section, but at least it is now more heavy duty

 

KNine

Active Member

• Feb 15, 2016

• #15

Looks good, excellent job, not seen that done before. It's quite low profile at the back, might be difficult to tighten roof tent bolts if someone wanted to do this for that reason. I am sure I still have my cross bars in the garage if you need more infill.

 

StuRox

Well-Known Member

• Feb 15, 2016

• #16

Cheers mate.

I wanted to try any keep it low and not increase the height to still get into car parks etc, as it was very limiting when i had the expedition rack on.

Not going to fit any more cross bars as I reckon 3 are enough as that's whats on the front bars and they are slightly longer than these ones.

Got enough room to fit roof box fitting or ratchet straps to tie down large items.

 

KNine

Active Member

• Feb 15, 2016

• #17

Excellent, job done.

 

StuRox

Well-Known Member

• Feb 17, 2016

• #18

Bit if a better pic, taken from the first floor to give you a better idea of what it looks like

 

needmoretools

Active Member

• Feb 17, 2016

• #19

It's a good idea that ive been meaning to do something about my roof rack just use some of my dads old paddy hoppkerk transit van ones. But they are bit high and fiddly to fit.

 

iwantone

Active Member

• Feb 22, 2016

• #20

That's some great work mate. Kudos.