Custom Roof Rack Installation

Here's a custom install of a Front Runner Slimline II Rack. Did not want the full expedition look with the rack sticking out and up - plus it would not fit in the garage/noise etc. Ordered a tray only the next size down (1475mm). Made some mounts out of 10mm thick aluminium angle, power coated them and mounted them to the 6 grab bar mounts (currently using the existing bolts as these have plenty of thread but some hi tensile ones are waiting to go in). Mounted 6 of the FR slats upside down to these mounts so that the load is directly on the mounts. Slats are gently touching the plastic roof runners to ensure they don't make any noise. One unsupported slat in the middle. Cut down the FR side extrusions and fixed them to the slats at the new spacing from the top. Front and end extrusions are close up against the last supported slat with minimum overhang and are slightly supported buy the roof rails.

Rock solid and very little give with 90 kg (+) point test load. No noticeable additional road noise.

Richard

Close up of the mounts.

Almost a perfect flush fit widthwise. There's a slight tapering of the grab bar mounts back to front.

Good work.
And you look like you are able to keep the kangaroos out of your manorial patch.
Nice wall!

RAS said:

Here's a custom install of a Front Runner Slimline II Rack. Did not want the full expedition look with the rack sticking out and up - plus it would not fit in the garage/noise etc. Ordered a tray only the next size down (1475mm). Made some mounts out of 10mm thick aluminium angle, power coated them and mounted them to the 6 grab bar mounts (currently using the existing bolts as these have plenty of thread but some hi tensile ones are waiting to go in). Mounted 6 of the FR slats upside down to these mounts so that the load is directly on the mounts. Slats are gently touching the plastic roof runners to ensure they don't make any noise. One unsupported slat in the middle. Cut down the FR side extrusions and fixed them to the slats at the new spacing from the top. Front and end extrusions are close up against the last supported slat with minimum overhang and are slightly supported buy the roof rails.

Rock solid and very little give with 90 kg (+) point test load. No noticeable additional road noise.

RichardView attachment 7849893

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All FR components supplied by Andrew at Maverick4x4

Tazzieman said:

Good work.
And you look like you are able to keep the kangaroos out of your manorial patch.
Nice wall!

Click to expand...

Wall is about 140 years old and is fully intact right around the house. Was a kitchen garden for the big farm the other side. Nearly 2 foot thick at the base.