Build Thread: Roof Rack For a JK Wrangler

[S.Bartfast]

Originally Posted by Lim@

do you think you actually needed to put the kink in the tub mounts? what was stopping you just have right angles and having a little gap between the body and the corner of the angle iron?

The hard top fits rather snugly to the tub and for the mount to nestle between the hardtop and the tub it really needs to hug the contours quite closely. I don't have a photo of it but recall that the hardtop has a flange extending down such that the bottom lip of the hardtop hangs down an over the side of the tub somewhat. The gap between the tub and the flange is so tight that I had to notch out that little window in the "foot" to get it to snug up to the hardtop as close as possible as even the seam in the hardtop bulged out too much for the bracket to fit. There is no way a straight 90-deg piece of angle iron will fit I'm afraid. You'll also struggle to get angle iron long and thin enough. I originally planned to start with angle iron and bend the curve into it but angle iron long enough was just too thick. That's why I opted to cut up 3mm hollow section instead.

Originally Posted by Lim@

i really like it though. i was considering a much simpler design but if you keep putting all your plans up then i'd be crazy not to atleast use them as a baseline! HAHA

If you are wanting to build something similar I will be more than happy to help you out with my designs. It is my intention to make the plans available when I have finished, I just haven't posted them yet as I keep making modifications.

The main thing is to get the dimensions of those two "hoops" correct, and as it is I fear I may have made it too high.

Originally Posted by Lim@

Why wouldn't you use a die grinder to scallop it? be a fair bit easier wouldnt it?

The simple answer is that I don't have one. Given the professional looking nature of the designs you may well be over estimating my workshop
Basically I'm just a backyard hack with an angle grinder, a drill and a big hammer

[Lim@]

Get a carbide die grinder bit for your drill. That should work I think

But cheers for that. Yeah I think I would be trying to have about 40-50mm clearance above the hard top. How stable is it with just the ladder installed? No front hoop? Being a 2 Dr if I can get away with just the ladder section then extend it out a little over the freedom panels that would be ideal. Especially with my snorkel. I'm sure I could make a front hoop easy enough. But no need really

[S.Bartfast]

Originally Posted by Lim@

How stable is it with just the ladder installed? No front hoop?

I've spent a bit of time trying to work out what you mean here. I can't imagine any reason you would want to get rid of the front hoop. If I'm not mistaken the 2dr wrangler actually has a longer gap between the front and rear bolts of the hardtop.

On the JKU these bolts are about 625mm apart:




Because the hardtop on the 2dr comes right the way up to the front door I believe you'll find this length is longer.

In any event it doesn't really matter how big this gap is you'll just make different length "ladder rungs" to suit.


What is important though is the width across the body of the car:




As you can see the with of the JKU tub is 1625mm at the front and 1580mm at the rear. A significant difference you must take into account during design.

Also, when you measure the span at the bolt holes be sure to measure from outside of the tub to outside rather than bolt centre to bolt centre. Your measuring the distance between the front and rear bolts centre-to-centre, but the tub width must be measured outside-to-outside.

If sent me the dimensions of your Jeep I'll easily be able to knock out plans for the hoops for you like this:

This image is by no means of "engineering standard" but it was more than enough for the guys at my local to knock up what I wanted.

By the way, I reckon this style of rack on a 2dr would look friken AWESOME!!!
In general I think the 2dr Jeeps look way tougher than the 4 and a 2-door with this style of rack would be something to be reckoned with!

[TheDoc14]

Love the way you attacked this, any updates on your rack..

[S.Bartfast]

Okay, for those following this thread, after quite an hiatus I'm pleased to say work on the roof rack has finally started to progress again and Post 3 (FABRICATION) has been updated accordingly.

[Lim@]

Looks really good mate. I know I said I was going to make one not long ago but I think I'll start in about a month. Is it possible for you to repost that first measurement sketch you had but with the shorter lengths to keep it close to the roof like you did.

[S.Bartfast]

Yeah, will do.
I'm posting with my mobile at the moment but can upload a new image when I'm next at my PC. The image well be exactly the same though, just with the legs 50mm shorter.