I wanted to share a recent modification I put together for my 2013 JKU Sahara incase it would inspire anyone since I believe it turned out well. I was frustrated with the options available of roof racks because as you all well know, the options are either gutter mount clamp cross bars, which aren't rated for that much weight, or something $500+ to get stronger support. My primary goal is to haul a couple kayaks and possibly other camping gear. I dont have any hard data but i believe two kayaks under interstate speed winds could exert more on the cross bars than what is rated for with the gutter clamp style.
I was highly interested in the Yakima RibCage setup because of its clean design and low profile rail system but didnt want to spend the money because the "ribcage" alone is $600 and including the cross bars, one is looking at about $1k. So since i didnt want to spend that, I decided to make my own. With my job as an engineer for industrial automation, I often use extruded aluminum t-slot framing for all sorts of build components. I noticed many rack systems have this channel adjustability and with the t-slot aluminum, that feature is baked in.
I understand that many people dont have this option but I utilized 3D printing to create custom frame roll cage clamp mounts that bolt to an 8020 angle component for the rear support. This is a nylon material so it will be very durable. I ordered all extruded aluminum and components through Tnutz.com. The bulk of machining i had to do was drilling and tapping a few holes but there was a section of aluminum angle that needed to be cut and some holes tapped for mounting the front support which sits above the rear passenger doors. I didnt have to cut any extrusion because it came pre-cut.
All in on supplies, I am in around $250-300. If there is interest, I can dive deeper into the material list, etc. Thanks!
I was highly interested in the Yakima RibCage setup because of its clean design and low profile rail system but didnt want to spend the money because the "ribcage" alone is $600 and including the cross bars, one is looking at about $1k. So since i didnt want to spend that, I decided to make my own. With my job as an engineer for industrial automation, I often use extruded aluminum t-slot framing for all sorts of build components. I noticed many rack systems have this channel adjustability and with the t-slot aluminum, that feature is baked in.
I understand that many people dont have this option but I utilized 3D printing to create custom frame roll cage clamp mounts that bolt to an 8020 angle component for the rear support. This is a nylon material so it will be very durable. I ordered all extruded aluminum and components through Tnutz.com. The bulk of machining i had to do was drilling and tapping a few holes but there was a section of aluminum angle that needed to be cut and some holes tapped for mounting the front support which sits above the rear passenger doors. I didnt have to cut any extrusion because it came pre-cut.
All in on supplies, I am in around $250-300. If there is interest, I can dive deeper into the material list, etc. Thanks!
