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50 Posts
I've got to give Twilightzero credit for most of the thought that went into this project. I just got my E a couple months ago and wanted to get a roof rack. So I started saving some $...and then I see it! DIY "Ghetto Fabulous" Roof Rack 2.0
I'm generally up for a good challenge (I do industrial machine repair) and can't believe I didn't think of making one to begin w/.
Now the wheels are turning, and I'm hoping to make some improvements to Twilightzero's design. The changes wont be cheap, but the rack will be cheaper than OEM/Yakima/Thule, and accessorizing will be easy.
My first e-shopping was done at WW Graingers.com and a search for "T-slot extrusion" showed me exactly what I was looking for.
2RCP8
I'll be using 2 of those cut down to 58-60", (I haven't decided on a length yet)
I've ordered slot covers to cut down on wind noise, end caps to give it a "finished" look, and a couple packages of nuts/bolts to hold everything in place. That totaled $102.xx from Graingers, and the M6x1.0x20mm bolts w/ lock washer and fender washers cost $20.91 (thanks ACEhardware
)
Total cost so far=approx.$123.xx
Checking McMaster-Carr showed me even more products and the prices (catalog) are cheaper for comparable products.
However Graingers is more convenient, I don't have to pay shipping, and I get a discount through my work account.
I was going to use 2"x2"x2" C-channel like Twilightzero, but a quick search of the scrap bin at work turned up some 2.5"x2" extruded aluminum I-beam. So that will become my stand-off(s) after being cut to size.
Alright, I didn't read his instruction thoroughly enough, and cut my pieces into 5-1/4" lengths which are too long. So they're going into the mill to be shortened tomorrow.
I'm generally up for a good challenge (I do industrial machine repair) and can't believe I didn't think of making one to begin w/.
Now the wheels are turning, and I'm hoping to make some improvements to Twilightzero's design. The changes wont be cheap, but the rack will be cheaper than OEM/Yakima/Thule, and accessorizing will be easy.
My first e-shopping was done at WW Graingers.com and a search for "T-slot extrusion" showed me exactly what I was looking for.
2RCP8
I'll be using 2 of those cut down to 58-60", (I haven't decided on a length yet)
I've ordered slot covers to cut down on wind noise, end caps to give it a "finished" look, and a couple packages of nuts/bolts to hold everything in place. That totaled $102.xx from Graingers, and the M6x1.0x20mm bolts w/ lock washer and fender washers cost $20.91 (thanks ACEhardware
Total cost so far=approx.$123.xx
Checking McMaster-Carr showed me even more products and the prices (catalog) are cheaper for comparable products.



However Graingers is more convenient, I don't have to pay shipping, and I get a discount through my work account.
I was going to use 2"x2"x2" C-channel like Twilightzero, but a quick search of the scrap bin at work turned up some 2.5"x2" extruded aluminum I-beam. So that will become my stand-off(s) after being cut to size.

Alright, I didn't read his instruction thoroughly enough, and cut my pieces into 5-1/4" lengths which are too long. So they're going into the mill to be shortened tomorrow.