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Plant Sky Vehicle Grille Automotive tail & brake light

RoxTerra Steel/Aluminum Drop in Roof Rack with vibration dampening
Info on the rack, prices, etc here:
Xterra Roof Racks, Molle Panels and accessories - roXterra Designs - Roof Racks and Molle Panels for Xterran Gen2 2005-2015 and Gen1 2000-2004

Features
  • drop in aluminum roof rack for Xterra 2005-2015 made from 1" aluminum tubing
  • 51 inches long, maximizing the available roof space
  • can carry over 100lb
  • the cushioned attachment to the roof rack is such that the mesh on top will not rattle off road, with or without a load
Installation
  • comes with all mounting hardware to your stock Xterra round bars
  • uses rubber padded attachment from stock bars, no drilling required
  • attach the rack to Xterra round bars, and tighten 8 nuts
  • vibration dampened roof attachment
  • U bolts with padding included, all you need is 9/16 socket to tighten the bolts
Usage
  • 6 heavy duty round luggage mounting spots (2 front, 2 back, 1 on each side) - 1 inch holes
  • enough room between roof and bars to run a securing rope without rubbing the roof
Delivery
  • ready within 3-4 days
  • free pickup in Tucson, Arizona
  • $30 once a week delivery to Phoenix
  • about $80 to ship
Following are the pictures of the steel model
Also showing here (in black color) are the Thule cross bars and Thule bike holders, attached because of the custom brackets (1) welded to the top of the rack
2) is a custom "wing" which allows attaching antenna with a magnet base to the roofrack , allowing for garage clearance.

Roof rack with mesh top - use any of the 100 or so holes for tying

2 Designs

Slim, U bolts face inwards:


Lowrider, U bolts face up:


Early days raw steel photos:
Raw steel pictures before powder coating - expanded metal mesh in first picture, and bars without that mesh in the following 2


Roof rack without mesh top
View attachment 123805
 

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Discussion Starter · #5 · (Edited)
Yes, full access to the box and handle. there is a 4" gap from the stock basket or 2 1/4" gap from that basket's handle in the pictures. And behind the basket I have room for my roof standing 12" antenna -- meaning that I could still move the basket backwards about 2", if I wanted more room by the basket instead.
You could mount the basket a little further/closer to front if desired, since the mounting spots to the stock roofrack can be moved.

If you mean the top brackets holding the Thule bars, they would be an additional option for $20. Mine has a threaded 1/4" hole in the bracket, socket-head bolt holding it. At some point this could become a bolt-on option if there is enough interest. My bracket was custom welded from 2 right angled channels (channel=2 sides of a tube shape), but it looks like it was factory made as one piece.

Roofrack too short? want to carry 12ft pipes on the roof?
The blue and green bars could be added, round of square. The dashed lines could be your own temp ideas based on your front bumper.
The rack is now 51" back to front. The blue addition would add 30", the dotted line is another 80".... maybe the dotted 80" could slide out from inside the tubes of the existing 81"?
It just takes one prepaid order to make that possible. Extra cost for that of course.

With the blue 30", that make 81" and would support the whole bed length, most of drywall... The basket would still open no problem. The 36" part could be a light mounting bar, square or round...

123810



Does this still allow full access to the roof box/handle. I like it. Also those welded brackets is that an additional option or part of the rack price?
 

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Discussion Starter · #6 ·
My cell signal boosting antenna doesn't get used often and it's nice being out of the way of my roof activities, flying highway objects... It's mostly used while the car is stationary.

That's a nice price for aluminum. Also, wouldn't you get a better ground plane with that antenna between the wet box and the rack :)
 

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Discussion Starter · #8 ·
Thank you very much, I have many ideas big and small, top, sides, back and maybe front someday. The bumpers design is already off the ground, with another model with dual swing gates coming in a couple of weeks, carrying a tire or not, maybe a ladder in addition/instead of tire, along with Hi Lift, gas cans...

I had a 6" tall Yakima roof basket on my stock setup, but even with just 1" lift it wouldn't clear the garage anymore. There was so much wasted space below the stock cross bars it was sitting on, then the mounting clamps on top of those bars...

And while carrying Hi Lift on the back bumper can be best sometimes, maybe out of sight on the roof can be sometimes or always better? And while Hi Lift can be mounted directly to stock bars, just wait until you hit your head on it once.... twice.... because it's sticking out away from the car

Nicely designed and well thought out
 

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Discussion Starter · #9 ·
Lowrider model (sits on top of stock bars with rubber padding) - Steel rack powder coated in King Sport Grey
The U bolts can also be powder coated to match the rack, here they are just original silver.
This is a very nice grey with smooth glossy texture.

124000


124001


124002
 

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Discussion Starter · #10 · (Edited)
Lowrider model - one can hold on to the square tubing on the way up to stand on a wheel
124003

Here the optional Thule bar mounts allow for Thule crossbars to sit above the rack
124004


2.5 gallon fuel cans could be mounted in the back corners
124005


3 1/2 inch height from the top of lower level to the top of upper level. (Could be taller with less than the above 1" of roof clearance.)
124009
 

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Discussion Starter · #11 · (Edited)
Slim model - unlike Lowrider, the U bolts mount sideways, not on top of the stock round bars
- only the area between the stock roof bars is used, leaving your existing mounts alone - like shovels/axes/Hi Lifts
This is an aluminum model and weighs just under 20 lb with mesh
124006


Here it is powder coated in black
124007
 

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Discussion Starter · #15 ·
Cost adds up with mesh cargo holder and powder coating, but
1) you could get creative with 1 inch belt-sized fabric and make your own "webbing", and
2) especially for aluminum, sand it by hand, prime it and spray can it, and it should be good to go
and
3) you could pick it up in Tucson or Phoenix, maybe also get the almost done rear bumper, or the coming soon curved 42" rooftop light holder. We have 70 degree sunny days now...

There is nothing like powder coating, but have you seen the hammered look spray cans?
 

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Discussion Starter · #18 ·
A mesh-only bottom is something we are working on, one that would need very little support under it, yet be strong enough for heavy loads. The grid while cool looking gets covered up with mesh anyway.
That could save $100
Partial mesh you put on yourself? We just finished a 72 hour adhesion of VHB 3M tape to attach aluminum mesh to a steel tubing bottom. Time will tell, but that's what the tape is designed to do, join metals that are powder coated
VBH link - https://www.3m.com/3M/en_US/vhb-tapes-us/

in the meantime...
With aluminum, you could sand, prime and spray can paint it yourself for just the cost of the primer, paint..... $20 ?
Even when it doesn't stick as well as powder coating, there is no rust concern anyway
- saves $100

Pick it up in Tucson as part of "Honey let's see the southwest which you always wanted to see" trip?
- saves $100

"Po boy December mesh discount"
- saves $40 on the mesh


Beautiful! I love the slim model with the mesh floor. But, with it being close to $700 (after $100 shipping), it's a little too pricey for me.
 

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Discussion Starter · #21 ·
expanded metal:
Yes I saw your rust issues with the expanded metal, many reasons why that could happen, like cheap powder coat material or application technique, improper sanding (sandblasting being preferred on steel) skipping steps in heat-to-remove impurities, let cool, heat again, spray, heat again process.... because powder coating should stick for.. very long time. Like with paint, some powder coats are just better.

How has your front bumper held up with powder coating, similar fate to the expanded metal? Both having been in the same environment... down here I was able to drive around with bare metal rack (uncoated) for about a month and pick up very reasonable amount of surface rust (very little). The sanding took it quickly away but sandblasting eliminated all signs of any surface imperfections from rust, mystery imperfections.


blue:
The blue was meant as making the 51" top support extend to 81" top support, in line with the existing 51" line.
I have carried beds, 16 ft tubes and other long things on the roof, and the front would flex in the wind.
Some people carry a lot of stuff, regularly or on some long trips, they cover the whole roof, the equivalent of 81" on Xterra. So one could use the cargo box and have stuff on top of it. Or go crazy on side lights? Or side mount something that fits within 30" or so. Something driver reachable?


shade bars:
I thought of adding some kind of shade/rain cover support with expanding side beams, like pullout arms to support the weight of the canopy. Tube into tube seemed cool, or telescoping round bars

So basically a DepHep but aluminum...? It is pretty awesome. If I didn't have my DepHep already I would totally be in for this. I don't carry much in my basket, and when I do it is not hundreds of pounds. I think this would satisfy 100% of what I have carried up there so far. The light weight and rust-resistance would be much preferred.

I'm trying to think of a use case for the blue & green to the front of the roof. The green could obviously have lights attached to it. Maybe you angle the blue part down to follow the wetbox lines and have low-profile roof light mount. But what could you put across/carry on the blue lines? Of course I would love to still be able to open the wetbox, but have that be usable roof rack space as well. Maybe that is not possible though. IDK what I might carry in that spot realistically.

 

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Discussion Starter · #23 ·
We would pick a setup that would be comfortable with 100lb in the middle.
Thicker mesh and 3 by 2 flat linear grid, as opposed to 3 by 8 tube offset grid.
Will someone want to carry 10 gallons of fuel, and a tire on a rim, and few other things at the same time? Then get the current heavier duty design.
Camping gear, 5 gallons of fuel, tire on temporarily? Thicker mesh and lighter support under it. The middle is most vulnerable so if you don't stack 2 tires on top of each other, it won't deform over time.

How much weight do you think a mesh-only bottom (no grid) would be able to hold? Thanks!
 

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Discussion Starter · #27 ·
We don't have the right thick mesh yet, so that design needs to wait.
We do have a simpler bottom base, instead of the 15 "openings" as below, there will only be 6 (3 up/down bars on the shorter side and 1 across).
The outside bars of the bottom will be channels (half tubes), and top will be tubes as now [saves on weight]
That design in bare aluminum is $350 with the mesh in December.
If you're cinching down something, you want to go around the bars not the thin mesh of this model, especially if you're ratcheting it. With the stretchy cords only cinched by their tension, the mesh holes are great. With the thick mesh someday, it still would be better to go with the stronger structural parts.

124149


Slim model, mesh, bare AL, picked up in Tucson over Christmas pricing? Ya think mesh only (no bars) will hold up even when one cinches down a load with ratchet straps? Price it with and without the underlying grid bars.
 

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Discussion Starter · #29 ·
A week to play it safe.

$350 ... Not too bad! Let me plan out my Christmas days and I'll get back to you in a day or two. My Dad lives in Tucson and I'm likely to drive down there from San Jose, could pick it up then. How many days leadtime do you need to build it?
 

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Discussion Starter · #30 · (Edited)
If you can pick it up in Eugene, Oregon, you can get shipping for about $30 for the next little while, because shipping can get combined with the rack that will leave in the next 2 weeks.
So if you order before March 8, that should work
Steel or aluminum, with mesh or not, powder coated or bare..........

Also if you're near Eugene, I may help you get $50 powder coating right there......

One of my rack's many uses. Stinky soil on the roof...
(Thule cross bar mounts are optional. I used to have bike carriers in the past, on the outside)
125801
 
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