Second Generation Nissan Xterra Forums banner

1 - 20 of 35 Posts

·
Registered
Joined
·
308 Posts
Discussion Starter #1 (Edited)
So I'm thinking about building a drop in basket of my own and thought I would bounce the design off some of you guys before I pull the trigger and order the steel. The entire thing will be made out of 2"x2"x1/8" angle iron and 1"x1/8" flat bar with an expanded metal floor. I wanted to make it as deep as possible so things aren't sticking too high up when its loaded and the plan is for it to sit on only the bars of the roofrack and not the end mount plastics. I was thinking if it is between raised plastic parts of the roof rack I could weld some low-prow unistrut on it that extends from the front of the wetbox to the very back of the rack. I'm hoping to use exhaust clamps and carriage bolts to mount it and keep a smooth looking top without drilling into the factory rack but I might just end up drilling instead.

My main questions are as follows:

1) Do I have the right dimensions? Yesterday I measured right around 32" between the bars but saw 31" mentioned in other custom basket threads. Likewise I measured 3.75" from roof to top of factory bar but haven't seen it mentioned in other threads.

2) Do you think it will hold together? The heaviest thing I will ever throw up there is a small Honda generator (~30lbs?) or a couple 5 gallon gas cans.

3) Any improvements to add to the design before I start building?

Here are some pictures of my design and an attached drawing pdf as well:



 

Attachments

·
Registered
Joined
·
308 Posts
Discussion Starter #2 (Edited)
This is what I meant about the unistrut along the roof rails which would then allow you to use a fey more pieces of unistrut as movable cross bars for accessories like kayak rack and roof top boxes.

 

·
Registered
Joined
·
3,797 Posts
My rack is basically flush with the top of the factory bar as checked with a straight edge. I can measure anywhere from 3.5" to 4.5" from the roof to the top of my rack depending on where I check.
 

·
Registered
Joined
·
308 Posts
Discussion Starter #5
My rack is basically flush with the top of the factory bar as checked with a straight edge. I can measure anywhere from 3.5" to 4.5" from the roof to the top of my rack depending on where I check.
Thanks! I figured on keeping it around 3.5" deep just be safe
 

·
Registered
Joined
·
1,693 Posts
Just gonna throw his out there.... MaxGear Drop in basket. Don't know what the price is, but they're butch.
Looks like he's shooting for around $400. Got his latest catalog the other day and he has them listed now. Looks pretty sick and a good contender to the Dephep one. Love how he's taken into account all the stuff people usually strap onto the bars from the get go.

 

·
Registered
Joined
·
3,797 Posts
Thanks! I figured on keeping it around 3.5" deep just be safe
Going off of my measurements 3.5" deep would touch the roof. I'd suggest taking something with a straight edge, like a 4' steel rule, and attaching a 12" rule to it sticking out 3.5" and putting that on the factory rails so you can see the clearance you've got. If my 3.5" measurement is indeed right I'd only go 3" deep at the most figuring you may have sag with weight on the rack, the material the rack is made of won't all be straight, and the body also flexes. I'd be real unhappy if I rubbed the paint off my roof :(
 

·
Registered
Joined
·
308 Posts
Discussion Starter #8
Just gonna throw his out there.... MaxGear Drop in basket. Don't know what the price is, but they're butch.
I think I saw what you're talking about, does he have a website or something I haven't figured out how to order his products. Also the materials for this should only cost around $150 with the expanded metal floor and unistrut so that's kind of a hard price for anyone to beat and then they would have to ship it.

I'm not trying to knock anyone's products (I'm pretty sure a blind woodchuck might be a better welder than me) I just enjoy building things and saving a few bucks and figure this should be a simple enough project to learn on.
 

·
Caretaker of The Minion
Joined
·
3,720 Posts

·
Registered
Joined
·
1,693 Posts
I think I saw what you're talking about, does he have a website or something I haven't figured out how to order his products. Also the materials for this should only cost around $150 with the expanded metal floor and unistrut so that's kind of a hard price for anyone to beat and then they would have to ship it.

I'm not trying to knock anyone's products (I'm pretty sure a blind woodchuck might be a better welder than me) I just enjoy building things and saving a few bucks and figure this should be a simple enough project to learn on.
He doesn't have a website but you can get a product catalog by emailing him. [email protected]

I think he has an instagram too but I'm not sure of it as I don't use IG.
 

·
Registered
Joined
·
308 Posts
Discussion Starter #11
Looks like he's shooting for around $400. Got his latest catalog the other day and he has them listed now. Looks pretty sick and a good contender to the Dephep one. Love how he's taken into account all the stuff people usually strap onto the bars from the get go.

Yup thats the one I saw and I really like that design but $400 is a bit out of the budget for right now. How do I find his catalog though?

Going off of my measurements 3.5" deep would touch the roof. I'd suggest taking something with a straight edge, like a 4' steel rule, and attaching a 12" rule to it sticking out 3.5" and putting that on the factory rails so you can see the clearance you've got. If my 3.5" measurement is indeed right I'd only go 3" deep at the most figuring you may have sag with weight on the rack, the material the rack is made of won't all be straight, and the body also flexes. I'd be real unhappy if I rubbed the paint off my roof :(
I like that idea! seriously I could not think of a good simple way to measure but I'll double check like this and make adjustments. Don't want to go messing up My pretty blue!!!
 

·
Registered
Joined
·
308 Posts
Discussion Starter #12
FYI if ya haven't seen my DIY version: http://www.thenewx.org/forum/23-exterior/166689-how-josx2s-no-weld-diy-roof-rack.html#post2613009

strong enough to hold at least my skinny @ss standing on it....150lbs ;-)
Ahaa! I have read yours as well and those dimensions are awesome thank you!

He doesn't have a website but you can get a product catalog by emailing him. [email protected]

I think he has an instagram too but I'm not sure of it as I don't use IG.
Thanks I'll send him an email when I'm ready(<---read: Wife will let me) for some bumpers!
 

·
Registered
Joined
·
308 Posts
Discussion Starter #16 (Edited)
Well I was able to get some welding done this weekend, at least until I ran out of wire... I'm using a Harbor freight 90amp Flux welder and am by no means a professional but I don't see this thing falling apart any time soon. I was only able to finish the outer square before running out of wire but here is a photo of it mocked up on the floor with the 1"x1/8" flatstock.

I set the depth at 3.5 Inches because that allowed me to use a 2x4 as a jig. It fits on the roof rack but does contact the center support feet of the roof bars. I'll be picking up some more supplies tonight after work and hopefully have this thing all glued together by the end of the night.
 

·
Registered
Joined
·
308 Posts
Discussion Starter #17 (Edited)
Small status update:
After finally picking up some more flux wire and new tips for the welder I have the "floor" of the basket welded up and the u-bolt holes drilled. So next up on the list is cutting unistrut to fit the top of the basket and welding it up top. Here are some test fit pictures from last night and hopefully I can get some more updates to you folks tomorrow.

















Oh and a little PSA to some: ALWAYS WEAR PROPER SAFETY EQUIPMENT!!! This happened last night due to my own misuse of tools (using a drill bit to ream out a hole). No one was hurt last night but just last year I had an 1/8" bit snap and end up lodged through my finger because I was too rushed to clamp down a workpiece.

Alright enough of my soap box ranting I'll see how much progress I can make tonight and update ASAP.
 

·
Registered
Joined
·
308 Posts
Discussion Starter #20 (Edited)
Alright tiny update time, the welding is done!!!!!




They are ugly but should hold up fine. I was able to get the basket and exhaust clamps primed last night so hopefully I will have it fully painted tonight and ready to install tomorrow.





I'll update with painted pictures tomorrow!
 
1 - 20 of 35 Posts
Top