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:compress: OK it's finally done. This may not be the answer to everyone's needs but was exactly what I needed.

Advantages:
Another place to throw stuff on your Roof.

It's ridiculously strong... I'm 175lbs. and completely comfortable standing in it.

Endless possibilties for bolting on accessories... Drill holes for anything, Light Tabs, Hi-lift, Shovel, Axe Mount, etc.

You retain Front Factory Basket with easy access to Rear Handle.

Overhead clearance

Lightweight... about 30lbs.

Disadvantages:
Will not fit a Spare Tire.

Cannot retain Stock Crossbars.

The Fab Build:
With the exception of the Welding this is a pretty simple build. I did all the fab in about a total of 2-1/2hrs minus paint time.
I used all 1/8" 6061 Aluminum so it's strong as a freakin Mack Truck.

Materials for Basket:
1-1/2"x25' Alum Angle
1"x25' Alum Angle
3/4"x21' Alum Square Tube
3/4"x21' Alum Square Tube

Material for Brackets:
1/8"x1"x3' Steel Bar
(4) 3/8"x4" Grade 5 Bolts
(4) 3/8" Grade 5 Nuts/Washers
(4) 1-1/2"Lx5/8" Alum Pipe for Bolt Sleeves
(1) Roll Double Sided Adhesive

Fab Cost:
Total Material: $97
Welding Labor: $80
Grand Total: $177 -- I'm pretty sure that's considerably less than a Loaded Warrior!

Edit: OK, got the Dimensions: 44-1/2"L x 32-5/16"W x 4"H
Depth is only about 3-1/16" due to Floor Height

The Brackets were the only thing I may have done different; in the process of bolting everything up I was thinking of ten other ways I could've made them, but trust me these are going nowhere. I measured them out to around 7-8" then hammered in the bend... No real science to it... After I drilled the holes everything lined up almost spot on so I was kinda lucky.

If you can't tell from the pics it sticks up about 3/4" above the Side Rails.

Getting started:



Mock-up:


Back from the Welder:






Resting neatly along Side Rail:


Handle clearance... You can see it better in the shadow:


Thanks for all the positive feedback guys!
 

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That is awsome. Great job!
 

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Very good job. I liked the solid construction of the rack and the fact that it was inserted between the rails and not on top as most are.
 

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how much for one shipped to MN :cheers:

Nice work I love how it's inside the factory rack.

Where you attached it, I can see the straps you attached to the X rack with, but does that bolt go through the rack you built, maybe I am missing something.
 

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I can see the straps you attached to the X rack with, but does that bolt go through the rack you built
Yeah, the Steel Strap Wraps almost 3/4's of the way around and the Bolt goes thru the Strap Holes and thru the Rack with an Alum. Sleeve/Spacer over the Bolt where it contacts the Factory Roof Rack.

Here's a pic:

 

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That is a sweet MOD! Does it affect your gas mileage? My load warrior does big time
 

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Been looking for a rack and the one you built actually looks like like one of the better ones I have seen......you need to start mass producing them :)
 

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has anyone done a modified version of this? I like the fact that it's all simple materials that i can cut myself and have someone weld for me. I would like to see this sitting a little lower if possible. How is the noise?
 

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Great looking rack!

Quick question...
For the Material for brackets:
You used 1/8"x1"x3' steel bar.
What kind of steel did you end up using?

I am looking at using t-bars for the lower part of the basket/rack instead of square tubes. In principle, it should provide a little more clearance without compromising on the strength. I'll post pictures when I am finished!

Thanks again for posting your rack.
Nic
 

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OK, This is probably one of the first 'How-to's' written & it is pre-DepHep Rack... All (11) Photos placed into PB's Purgatory, have been Resurrected for this Thread! :thumbup:
 

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Yeah, the Steel Strap Wraps almost 3/4's of the way around and the Bolt goes thru the Strap Holes and thru the Rack with an Alum. Sleeve/Spacer over the Bolt where it contacts the Factory Roof Rack.

Here's a pic:


Do you have a link to where you purchased the straps and spacer? I know this thread was a few years ago...
 
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