Here's the roof rack I made. Don't be too tough on me, some things I would have done different if I was going to do it again. I haven't made the basket yet or the attachments to hold my canoe (still trying to figure out how I'm going to do that). I can remove the rack by 4 clevis pins. I haven't hooked up the lights yet either. The last picture is my Jeep when I bought it about 6months ago.
It is 1" sq tubing that I already had. I attached the front by making a right angle bracket that attaches to the hinge plate for the windshield on the bottom. On the top front the 1" tubing fits inside a sleeve and is secured with a clevis pin.
I have about 40 hours in it, mostly cleaning up the metal I used. It was all used metal welded together. Had to cut apart sand and paint, but it was all free. Jeeperzcreeper if you are interested I can send more pictures to your email but I never did write anything down. If you have the tools required and the metal its worth it. If you have to buy anything its cheaper almost to buy a new one. I used a Mig welder, gas torch set, 4 1/2 grinder, metal cut off saw, sawsall, and misc hand tools. I just like making my own stuff.
some things I would have done different if I was going to do it again.
How about sharing your thoughts on this as well? Otherwise it does look nice. I have a Warrior Product roof rack I removed from my Jeep when I got it - didn't like the look.
97 TJ 6cyl, 5speed 37" Krawlers on American Racing 17" wheels. (Beadlocks someday)
RE 5.5 Long arm, Currie 9" front and rear with ARB's, Warn hubs and axle shafts, CTM u-joints
Optima Dual Batteries, OR Fab roll cage, custom rock sliders, SMF shorty bumpers front and rear.
My Jeep Site: www.jeffsjeep.com
Some of the things I would have done different is I would have put hinges on the back braces to make it easier to remove, I would have followed the contour of the roof more closely to cut down on wind noise, I would have made it disconnect in the front so when I took the rack off it still would have the light bar on to name a few. I'm out of town all this week so I'll try and post some close-ups Sat. of the connections.
Your Jeep looks great man, I'd love a roof rack but not sure how much I'd use it. I have those same black tubular bumpers and was thinking about buying and installing a winch but its not quite a recovery bumper; how do you like yours?
One must learn by doing the thing; though you think you know it; you can't be certain until you try.
Just a suggestion for hooking up the lights, use a 4 pin trailer harness, one wire for each light, and ground then to the rack. Then when you take the rack off you can diconnect and reconnect the lights real easy.
I have just a light bar over the windshield, and I ran the power wires down the inside of the tubing, and then flattend the wires ran them behind the antena and into the engine bay at the back of the hood.
What have we got?
We have one heavily armed Recreational Vehicle