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DIY: Drop in Cargo Roof Rack - “The Golf Cart Roof Rack Hack”

64K views 134 replies 46 participants last post by  Jeradk43  
#1 · (Edited)
Hi All,

Been searching for a relatively inexpensive roof rack option (so a DIY), mulling over all them, and finally came across THE one (shout out to wstark for the idea) !

It's made for a golf cart - and looks like the Garvin roof rack


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  • The only roof rack storage system of its kind on the market.
  • Great for hunting, storage, hauling, luggage and more.
  • Fits E-Z-Go Medalist/TXT 1994.5-2013.
  • Heavy duty black powder coated steel construction.
  • Rack measures 5"H x 32"W x 52"L.
  • Easy to install with custom brackets designed for each roof style.
  • Includes roof rack, installation hardware and mounting brackets.
  • Some drilling required.
Found a 10% off coupon code online (“EC10”), and got it for $204.00 shipped to my door step (no tax, free s/h)!

Next, ordered four Vibration-Damping U-Bolts from McMaster-Carr, roughly $45.00 shipped


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Items arrived in less than 5 days...

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Used a speed square to get centers, used a punch to get nice dimples, and got to Drilling

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Mounted it up !

Also used bike tube as an inner liner for this particular Ubolt housing/bracket (as others have suggested before).
A couple shots of WD-40 also helped get the Ubolts on the vibration damping housing, and through the drilled holes in the rack.

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Everything fits perfectly snug ! Almost as if the rack/bolts were intentionally designed for this application.

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Able to access the wet box no problem, as well !

In short, a Garvin like rack for $250 !!

The chrome bolts are bugging me though, I'm gonna scuff them up and paint them black.
 
#5 · (Edited)
There’s no weight limit listed, but it has withstood the “I’m 250lbs and stood on it, no problem” weight test from someone else. Considering the factory xterra limit for the stock rack and crossbars is 150lbs I think it’s good to go. It is solid!

My initial plan was to go with the ubolt threads facing down, running unistrut bars as cross bars, and mounting the rack to the unistruts. Then using the unistrut ends on one side to mount an awning. Might still do that down the road...
 
#7 ·
My initial plan was to go with the ubolt threads facing down, running unistrut bars as cross bars, and mounting the rack to the unistruts. Then using the unistrut ends on one side to mount an awning. Might still do that down the road...
That is what I did with an ARB awning, then I got a drop in rack and had to redo the awning mount. Now I have a 23Zero awning and (1) the mounting hardware is far superior to ARB and (2) mounted perfectly using the mounting spots for the rack.
 
#8 ·
Shiiiiiiit man, that's the cleanest and by far the easiest option I've seen. My rooftop platform via How-to: Cargo Carrier Converted to Roof Rack is nice especially because it's a little more stealthy, but man it's a total pain in the ass to mount and remove, plus I sometimes yearn for the side-walls all the way around. I definitely might go this route and replace mine in the future and look to add a wire mesh floor across it plus some D-rings.

Good lookin' out, you two.
 
#15 ·
Thanks CDL. Newbie question, since I haven't taken an adventure since I got the vehicle 3 weeks ago. What types of things would you use the rack for? Are those storage boxes what you will use up there, because they fit perfect? My off-road driving will be mostly on the beach on the eastern shore of MD. Day trips, maybe a camp overnight. Like to do the canopy install also, would the 2 mods work together? Novice questions, I know. Thanks
 
#16 ·
Yep, the awning will fit depending on how you mount the unistruts: Unistrut / Superstrut Crossbars and Rotopax / Treds /...

it was a two person effort getting those fully loaded boxes up top (my 3 bin car camp set up).... told my wife, I “need” a gobi ladder now. Lol

i’ll probably end up putting lighter bulky items up there; tent, standard 10x10 canopy, folding chairs, sleeping bags.

which will leave room for the three bins, cooler and fire wood in the rear cargo. Right now, everything fits in the rear but i have zero visibility out the back window.
 
#17 ·
Yep, the awning will fit depending on how you mount the unistruts: Unistrut / Superstrut Crossbars and Rotopax / Treds /...

it was a two person effort getting those fully loaded boxes up top (my 3 bin car camp set up).... told my wife, I “need” a gobi ladder now. Lol

i’ll probably end up putting lighter bulky items up there; tent, standard 10x10 canopy, folding chairs, sleeping bags.

which will leave room for the three bins, cooler and fire wood in the rear cargo. Right now, everything fits in the rear but i have zero visibility out the back window.
Just by looking at it, I know my awning mounts (which are just muffler clamps with an L-bracket) would fit no problem, if you had to go a different route.
 
#19 ·
By looking at it, the height is all dependent on where you decide to drill into the rack, and @CDL appears to have put it at the highest possible position which is good to know. I'd love to see someone do this and mount it with a minimal amount of space underneath without touching and see how it looks.

I feel like "upgrading" to this is definitely in my future at some point.
 
#22 ·
I’d like to see a lower mount as well. It does indeed look like it’s higher up and could possibly go lower.

@CDL - do you think that the top of the rack could sit flush with the tops of the rails? Or is it too deep to get it that far down? TYIA.
 
#28 ·
Cut strips of bike inner tubing to wrap around the factory rail, and ubolt bracket over that. Fills in the ever so slight diameter gap/difference between rail and ubolt bracket, and creates more friction to hold it in place.

Links are in the first post.
 
#24 ·
I measured the height of the X's roof to top of OEM rack sidebar = 4.5". The cargo rack is 5"H. Depending on the load and flex of the cargo rack base, it's going to stick up above the rails. I would be cautious about mounting it too low and scratching your roof. Lost in this conversation is the sweet McMaster Carr dampening U-bolts. Great find that could have application beyond a cargo rack. Thanks CDL, and the code worked.....dammit :) $201.60 free shipping
 
#25 ·
OK... to make thins easy for all, since our various rigs sit at different heights, put a level or something stiff and straight from one side of the rack to the other. Then measure down to the roof, preferably on a rib. Once you have that measurement, anyone can figure out if the rack setup as shown will fit in their garage.

In my case.... my garage door header is 82 inches from the floor. The weather strip deletes an inch from that. When I back my rig into the bay my awning just touches that weather strip. I have 81 inches of clearance total. The DepHep rack sits ontop of the stock rack rails, and the awning mount bracket sits ontop of the rack. From the ground to the top of the awning is 80.5 inches.
My driveway has a slight rise just as you enter the garage door, so I'm not entering flat but at a slight angle.

To mount the rack as close to the roof as possible, I'd take some 1/4 inch spacer slats and put them on the roof and put the rack on them. Then I'd fasten the rack to the stock rails. Finally I'd remove the spacers. Easy peasy.
 
#31 ·
@CDL - thanks for the excellent op and follow up posts. All the detailed pics are friggin gold.
You really brought a gem to the crew. I see MANY folks going with this option.
 
#43 ·
God, it's killing me how quickly and easily y'all are completing this.

Any ideas for adding a floor or some cross bars for extra support for standing up on it? I use my current rack as a platform for photography or just sitting up there. That's the only thing missing from this for me and I'm thinking of different options, removable or permanent.
 
#44 · (Edited)
...Any ideas for adding a floor or some cross bars for extra support for standing up on it?...
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Unistruts (at the local home improvement store) with same McMaster-Carr Ubolts!
Endless possibilities... note the hi-lift mount using the unistruts... vision an awning on the other side, or shovel/axe mount... plus golf cart rack... rack will sit a bit higher with this configuration, but not that much
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EDIT: due to basket width, it will need to be notched to fit the ubolts in a unistrut below the rail position. Unistrut above the rail no problem, of course... but it’ll be sitting high.

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