Drop-in Basket Concept - Page 3 - Second Generation Nissan Xterra Forums (2005+)
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post #21 of 35 (permalink) Old 05-24-2017, 06:35 PM
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Are or have you done any load tolerance testing on it yet? I'm designing and welding a rack for mine too and didn't think shying away from tubing would provide enough strength. Though, I suppose it only needs to be strong enough to hold what you are tossing up there.

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post #22 of 35 (permalink) Old 05-25-2017, 09:01 AM Thread Starter
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Originally Posted by Desert-X-Guy View Post
Are or have you done any load tolerance testing on it yet? I'm designing and welding a rack for mine too and didn't think shying away from tubing would provide enough strength. Though, I suppose it only needs to be strong enough to hold what you are tossing up there.

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No I have not done any testing or simulations on this design and I don't really plan on doing any. I have learned a lot while building this and might attempt a version 2 in the future just because it was a pretty fun project. I know the outer frame isn't going to fail from anything I could throw at it but the flat stock floor I'm having some second thoughts about. My plan is to throw something in the basket as a floor but that will likely add enough thickness that I should have done tubing to begin with. I guess time will tell and I'll try and remember to keep this thread updated as time goes on.

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post #23 of 35 (permalink) Old 05-25-2017, 09:21 AM
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Just a thought on the cross bars to save weight instead of using square tubing but still increasing the strength and rigidity you could always use 1" angle iron with the wide side up and the 90° down or just on it's edge. Either way it would be half the weight of square tubing.

Something like this:

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post #24 of 35 (permalink) Old 05-25-2017, 09:56 AM Thread Starter
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Update 05/25/2017:

This thing is done!!!!! It didn't turn out exactly how I had planned or hoped but I'm still happy it's finished and proud that I did it myself.

Photobucket is being a pain right now so I'll have to share the finished pictures later...
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post #25 of 35 (permalink) Old 05-25-2017, 09:58 AM Thread Starter
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Originally Posted by Allshookup View Post
Just a thought on the cross bars to save weight instead of using square tubing but still increasing the strength and rigidity you could always use 1" angle iron with the wide side up and the 90° down or just on it's edge. Either way it would be half the weight of square tubing.

Something like this:
I had though about that as well but planned on it being too close to the roof to pull that off. Now that it is mounted, it definitely came up high enough to use the angle which might be part of version 2.

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post #26 of 35 (permalink) Old 05-25-2017, 11:53 AM
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Did you grind off all of the electro galvanized finish off the superstrut to weld it? I love that stuff but never considered welding it because of that unique finish they put on it.

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post #27 of 35 (permalink) Old 05-25-2017, 01:33 PM Thread Starter
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Did you grind off all of the electro galvanized finish off the superstrut to weld it? I love that stuff but never considered welding it because of that unique finish they put on it.

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Yes I ground the finish everywhere that I welded but that still wasn't enough, During welding the finish started flaking off from the heat so I held my breath, kept the garage door open, and got it done as quickly as possible because welding on galvanized material is a big no no and makes some fumes you don't want to be around.

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post #28 of 35 (permalink) Old 05-25-2017, 01:51 PM
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Yes I ground the finish everywhere that I welded but that still wasn't enough, During welding the finish started flaking off from the heat so I held my breath, kept the garage door open, and got it done as quickly as possible because welding on galvanized material is a big no no and makes some fumes you don't want to be around.
Lol, you should be wearing a respirator anytime you weld anything (they make low profile ones to fit under your mask) and I only weld galvanized outside and with a couple high cfm fans to help with fumes.

I figured that finish would be a nightmare. Great stuff for lots of things but welding... Not so much

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post #29 of 35 (permalink) Old 05-25-2017, 02:52 PM Thread Starter
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Photobucket is back to working!!!!

Here's the basket all bolted to the roof:








And here are the low pro unistrut cross bars added. I made sure to tighten these down with my tool kit under the back seat so I know I can adjust their position anytime I need too. Also have one more extra in the garage that I'm thinking about using for a bicycle fork mount in that back of the Xterra.






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post #30 of 35 (permalink) Old 06-07-2017, 09:38 AM Thread Starter
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Just a little update on the basket, I've been using it to haul kayaks the last couple Fridays with the wife and threw a dewalt tough box up there for giggles:







I did mess up and get bolts that were a little too long but found that they can be easily shortened on a bench grinder. If anyone is interested in the correct length bolts to use in lowpro unistrut I can get a measurement later.

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Last edited by Hawk136439; 07-20-2017 at 10:24 AM.
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