Another take on DIY cross bars

Discussion in 'Fabrication' started by HoosierJeeper, Dec 17, 2012.

  1. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    Total price...$37.
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    Just some conduit hanger and 2 48" 3/4" dia (I think) conduit bars. I'll post some pics of the hardware if anyone wants to see it. Couldn't find those other things for the low profile ones and I wanted the bars higher to allow for ski/board bindings. That's all I'll be using the rack for anyway.
     
  2. Jo6pak

    Jo6pak Full Access Member

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    HJ, please post a materials list andquick write up on the process. There have been only a few times that I wished I had crossbars in the past few years, but since I'm a cheap bastard, I never got around to making some.
     
  3. yellocoyote

    yellocoyote Administrator

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    Nice job. Looks like they sit up pretty high though - would like to see clearance between roof and cross rails.
     
  4. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    In the electrical section at Menards, get #2 conduit hanger and the next size smaller. Get 4 of each. You can use the supplied hardware, but I got some locking nuts, size 4-20 IIRC. Notice the carriage bolts. When you assemble them, put the small hanger on the larger one, perpendicular to each other, use 4-20 1/2" screws and nut there. The larger one goes over the factory rails, the smaller ones sit on top and that's where the bar goes through. That's about it...paint before assembling if you want. They are really sturdy. Also use some pipe insulation if you want to protect the factory rails. Tool wise a philips, a 7/16" deep well socket, 3/8" ratchet, a 7/16" nut driver and a vise to hold the nut driver while you screw the things together. Not sure how clear that is...

    I'll get pics....but it's 4-5" I think.
     
  5. Jo6pak

    Jo6pak Full Access Member

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    Thanks HJ, the description makes sense. Might be a good winter day project, just so I have them on hand if I need them.
     
  6. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    No prob.
     
  7. Austerity

    Austerity Full Access Member

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    I don't want to be a pain, but any chance you could post some pictures with better lighting/focus of how the bars are actually mounted? I'm trying to work with your photos but they are dark :D

    Thanks
     
  8. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    Sure, I'll get some later tonight.

    While at Menards tonight, I looked at the sizes again, #2 for attaching to the OE rails then #1 for attaching the 3/4" conduit.
     
  9. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    Are these better?
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    The #2 mounts on to the OE rails then the #1 sits on top of those perpendicularly (the cross bars go through them) Oh, and assemble them before mounting (put the #1 on the #2).
     
  10. Austerity

    Austerity Full Access Member

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    Yes, very helpful.
     
  11. jeepHead

    jeepHead New Member

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    I am going to do this, I was going to use steel pipe (gas lines) pretty heavy though) how much weight do you think the Conduit would hold? I don't carry lots of weight, but would be good to have a reference...also, how did you cap the ends?
     
  12. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    It'll hold over a 200lbs I bet, it's stronger than the OE rails for sure, that's the weak link IMO. I just used the caps that came on them.
     
  13. jeepHead

    jeepHead New Member

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    Thank you, that is very helpful!
     
  14. jeepHead

    jeepHead New Member

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    I did it and it was definitely cheaper than I thought, total cost from materials at home depot was under $15.00 I also found a broken treadmill and took the band off (is thin rubber with a fine sandpaper-like texture to prevent slipping, I cut long strips, coated the conduit with high strength adhesive and covered it with the rubber instead of painting them..thanks again for the idea!
     
  15. HoosierJeeper

    HoosierJeeper Gold Supporter/Admin Staff Member Administrator

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    Cool...glad you like them!