Stock OEM Roof Rack Tool Mounts

tnegiet · 10-07-2006, 04:04 PM

Finished products, see post #17:

I've been working on a Hi-Lift, axe, shovel, and fire-extinguisher mount for the stock roof rack. Like all of you I have waited patiently for something reasonable to come on the market.

My goal was to have the mounts on the outside of the rack so I can still use the interior of the rack for either my Thule cargo carrier, spare tire, basket, whatever. There was no reason to re-invent the wheel, so I simply started looking for 1.75" roll-bar clamps that are used in the auto racing industry. The roll-bar clamps were purchased from two different companies, one in the northeast, one in the upper midwest. The clamps are annodized billet aluminum that cost approx. $10 each. Total cost of the 3 clamps, shackle, hardware, and coating was $55.

I first started working on the Hi-Lift mount. The Hi-Lift weighs approximately 40 pounds which is certainly a concern when clamping it to the roof rack. In order to ensure that the Hi-Lift could not loosen and dent the roof I connected two clamps with a 3 1/8" shackle. The shackle is the mounting point for the Hi-Lift. By using this configuration it is impossible for the Hi-Lift to fall and dent the roof even if the rear clamps are completely loose. The front of Hi-Lift is bolted directly to the clamp. Both the front and rear roll-bar clamps are angled upward about 15 degrees so that the Hi-Lift settles in toward the roof rack.

I tried several different bolt and nut/washer configurations before I settled on what I will use. To connect the shackle to the roll-bar clamps I first used 1"x1/2" Allen Head bolts, but I later switched to 1"x1/2" zinc hex head bolts. I can get them tighter and they match the zinc hardware on the Hi-Lift. The shackle was Rhino-Lined but could also be powdercoated. The center mounting bolt is a 2-1/2" zinc hex head bolt with a 1/2" wingnut. The front of the Hi-Lift is a 1" zinc hex head bolt. I tried different washers, lock washers, and locking nuts. I don't believe lock washers are necessary.

I have not finished the axe, shovel, and fire-extinguisher mounts. I'm connecting Quick-Fist mounts to these same roll-bar clamps.

fjtribe · 10-07-2006, 04:38 PM

Very well done. Looks OEM and like it should have been there. I was thinking that if you used bolts threaded all the way down, you could run a nut down on it before you put the spcer on and it would be solid and hold the bolt secure while you take the windnut off. Also, if you're having trouble holding the handle on, you could use velcro strips or wireties. All in all, nicely done...2 thumbs up.

FJ #8 · 10-07-2006, 04:41 PM

very nice job,looks really good

tnegiet · 10-07-2006, 06:09 PM

Edited original post:

The clamps are annodized billet aluminum that cost approx. $10 each. Total cost of the 3 clamps, shackle, hardware, and coating was $55.

Also, the clamps are threaded on the inside so I plan on building a basket that would fit recessed inside the OEM rack that could be easily bolted to the roll-bar clamps. Or, you could insert some eyebolts, or bolt a tire carrier, or...whatever.

tnegiet · 10-07-2006, 06:14 PM

Quote:

fjtribe previously said:

Very well done. Looks OEM and like it should have been there. I was thinking that if you used bolts threaded all the way down, you could run a nut down on it before you put the spcer on and it would be solid and hold the bolt secure while you take the windnut off. Also, if you're having trouble holding the handle on, you could use velcro strips or wireties. All in all, nicely done...2 thumbs up.

A fully threaded 2-3" bolt would work fine, however you still need a small spacer to keep the Hi-Lift away from the rack to prevent rubbing. The main bolt does cannot come out due to the location between the two clamps. So, even if it did come loose it simply doesn't matter. Fully threaded bolts in higher grades are difficult to find, I'm still looking for them...

The handle is temporarily taped simply becuase my rubber Hi-Lift handle holder hasn't arrived in the mail yet...

bandi · 10-07-2006, 06:20 PM

VERY Nice Tnegiet !!!... I Like that you came up
with a Cheap Mod that anyone could do...

Plus No Welding !!! VERY SWEET !!!
Kudos my Friend !!!

trackerbb · 10-07-2006, 08:16 PM

Nice work. looks great. The high lift jack is my next concern. You nailed it.
Gonna patten pend that idea? Looks like a money maker to me.

**Corey** · 10-07-2006, 10:01 PM

Looks good, and certainly cheaper than the almost $100 with shipping I just spent on mine.

bandi · 11-06-2006, 06:13 PM

Quote:

tnegiet previously said:

.... The roll-bar clamps were purchased from two different companies, one in the northeast, one in the upper midwest. The clamps are annodized billet aluminum that cost approx. $10 each....

tnegiet Sir... Do you have a name, or web pagee for the clamps ??? PM Me PLease... Thanks Sir...

**redfernsoljah** · 11-06-2006, 06:20 PM

Great Application! Good Work! You Should put more of these together