http://www.youtube.com/watch?v=CkxAYcmaex4&feature=plcp
Low profile roof rack - Homebrew :o)
Moderator: volvite
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Wearethesound
- Posts: 13
- Joined: Wed Oct 26, 2016 10:28 am
- Location: United Kingdom
Resurrecting old thread. I also live in the U.K. And just bought a 2007 pathy and looking to do something like this to mine as well as I haven't been able to find a system that completely replaces the OEM rails as I'm not a fan of the racks that sit on top of them. Anything you would do different or have changed? Do you happen to remember the wall thickness of the tubing?
Don't recall. I bought the tubing from our local B&Q.
Where abouts are you? I ask as I've sold the Path finder earlier this year so the Rack is available for sale if you are interested. Would need collecting and needs a repaint. Otherwise it's as the video.
I also made some roof bars for my large Canoe that fit with the rack as well.. real good combo if you have bike racks to add. There's an additional bracket that slots on to the roof rack bars allows a set of telescopic ladders to be propped against the roof rack system. Ideal for getting bikes up and not damaging the side of the car.
I'm in North Staffs.
Where abouts are you? I ask as I've sold the Path finder earlier this year so the Rack is available for sale if you are interested. Would need collecting and needs a repaint. Otherwise it's as the video.
I also made some roof bars for my large Canoe that fit with the rack as well.. real good combo if you have bike racks to add. There's an additional bracket that slots on to the roof rack bars allows a set of telescopic ladders to be propped against the roof rack system. Ideal for getting bikes up and not damaging the side of the car.
I'm in North Staffs.
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Wearethesound
- Posts: 13
- Joined: Wed Oct 26, 2016 10:28 am
- Location: United Kingdom
Re: Low profile roof rack - Homebrew :o)
@elpeede - I realize this post is old, but thanks for this thread and your youtube video. It inspired me to build my own low profile roof rack after having a lot of difficulty finding a factory replacement I was comfortable with. Your posts saved me some $ and time 
. I went with a no weld solution using aluminum Unistrut. Sharing here in case it is helpful for others.
- Cut the unistrut to size with carbide recip saw. Note that the length between the front and back of the rails are different! I almost made this mistake.
- Mapped the bolt-hole positions by marking them on a piece of clear poly-carb sheeting then drilled through the poly-carb and into the unistrut to get a match. This is tricky because the factory rails are curved across the roof line. My results were not exact so I needed to increase the hole size to properly thread the bolts. Ultimately I was able to secure 6 of the 7 factory bolts with this design.
- Painted the strut with Dupli-color Bed Spray liner. I do not recommend this product. Despite adhering to every instruction and all the prep work, the bond to the aluminum is poor. It took multiple coats to get acceptable coverage. Even with all that, is is starting to peel off with any contact to equipment.
- Cut some angled aluminum to attach a few Quick Fits for my shovel and axe.
My guess is that this at least will support 200 dynamic pounds which I read was the limit of the OEM rack. Heaviest I have tested so far is a 70lb canoe. No issues.
Again, thanks elpeede!
. I went with a no weld solution using aluminum Unistrut. Sharing here in case it is helpful for others.- Cut the unistrut to size with carbide recip saw. Note that the length between the front and back of the rails are different! I almost made this mistake.
- Mapped the bolt-hole positions by marking them on a piece of clear poly-carb sheeting then drilled through the poly-carb and into the unistrut to get a match. This is tricky because the factory rails are curved across the roof line. My results were not exact so I needed to increase the hole size to properly thread the bolts. Ultimately I was able to secure 6 of the 7 factory bolts with this design.
- Painted the strut with Dupli-color Bed Spray liner. I do not recommend this product. Despite adhering to every instruction and all the prep work, the bond to the aluminum is poor. It took multiple coats to get acceptable coverage. Even with all that, is is starting to peel off with any contact to equipment.
- Cut some angled aluminum to attach a few Quick Fits for my shovel and axe.
My guess is that this at least will support 200 dynamic pounds which I read was the limit of the OEM rack. Heaviest I have tested so far is a 70lb canoe. No issues.
Again, thanks elpeede!
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Re: Low profile roof rack - Homebrew :o)
Good job Jmo!
(I also wish elpeede would drop by sometime again)
(I also wish elpeede would drop by sometime again)
Re: Low profile roof rack - Homebrew :o)
long time observer, 1st time contributor...
here's a diy roof rack i put together Dec.2020.
Superstrut, some hardware, commercial black coated steel grid, flat bar, 32" slim led bar.
No welding. Just a drill, jigsaw & hacksaw, and hand tools.
I'd have to double-check receipts, but I'm pretty sure the total investment was less than $175.
Just wanted to add to the gallery of possibilities for anyone looking to do something creative...
here's a diy roof rack i put together Dec.2020.
Superstrut, some hardware, commercial black coated steel grid, flat bar, 32" slim led bar.
No welding. Just a drill, jigsaw & hacksaw, and hand tools.
I'd have to double-check receipts, but I'm pretty sure the total investment was less than $175.
Just wanted to add to the gallery of possibilities for anyone looking to do something creative...
- before paint and light bar
- after paint and light
Re: Low profile roof rack - Homebrew :o)
Great post!myself wrote: ↑Mon Apr 12, 2021 6:23 pmlong time observer, 1st time contributor...
here's a diy roof rack i put together Dec.2020.
Superstrut, some hardware, commercial black coated steel grid, flat bar, 32" slim led bar.
No welding. Just a drill, jigsaw & hacksaw, and hand tools.
I'd have to double-check receipts, but I'm pretty sure the total investment was less than $175.
Just wanted to add to the gallery of possibilities for anyone looking to do something creative...
20201231_154357-01.jpeg
Screenshot_2021-04-12-21-27-09.png
Screenshot_2021-04-12-21-27-03.png
Screenshot_2021-04-12-21-26-57.png
this thread is really coming together as a valuable tool for membership.
Re: Low profile roof rack - Homebrew :o)
Added a small 12" single row bar to the rear of the rack (you know- to see where i've been), wired thru an aftermarket master switch in the factory blank position by the shifter, and added a 3way toggle switch to send power from the master switch to the relay for the top bar when switched forward, and the rear bar when switched to the rear position. The toggle is installed out of sight, but easily reachable, on the tiny flat spot where the center stack trim meets the steering column / driver area trim.
Wasn't sure whether it was most appropriate to add to this section, or the electrical section- but it goes along with the roof rack so here it is...
Wasn't sure whether it was most appropriate to add to this section, or the electrical section- but it goes along with the roof rack so here it is...
- rear mini bar
- rear mini bar side
- oem style master switch
- hidden toggle switch
Re: Low profile roof rack - Homebrew :o)
Myself:
This has turned into such a great thread with the help of the membership such as yourself, I will promote it to sticky.
This has turned into such a great thread with the help of the membership such as yourself, I will promote it to sticky.
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donaldpath
- Posts: 15
- Joined: Thu Oct 28, 2021 1:14 am
- Location: California
Re: Low profile roof rack - Homebrew :o)
How much of a difference in length is it between front and rear crossbars? I did just a rough measurement, and both from and rear crossbars measured the same length.
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