How to Build a Roof Rack

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By MyJB
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Roof Rack

Car roof racks are designed to transport items that are too large, bulky, or cumbersome to fit into the vehicle. The roof is a perfect place for such items. However, to protect against items sliding from the roof and landing or crashing onto the road and harming other drivers, the objects must be secured to the roof of the car. There are racks for cars, vans, SUVs, stations wagons, trucks, buses and jeeps. They are used to transport skis, bikes, boats, building materials, and other possessions that can't fit into the vehicle. Although racks can be custom made to fit any vehicle, a simple standard design has cross bars, floor with slats, and guard rails, similar in design to a large basket. There are also very plain roof racks that have two cross bars and two side rails only. The design of the basket corresponds with it's purpose. A different roof rack is needed for skies than for luggage.

To build a simple roof rack you need: tower, crossbars, and side rails, protective center slats, self-sealing screws and a drill. Assuming that your car already has the raised side rails, you can proceed with building your rack. The towers need to be attached to the vehicle before the rack can be attached. The towers are the support for the rack and are raised fasteners that support the roof rack on all four sides. Two are placed on each side of the car. They are made of stainless steel, zinc, aluminum, or nylon. The towers come in different styles and can be attached to the car in different ways. This tower is attached to the side rails. Already on the vehicle are side rails. Once the tower is in place the cross bars can be inserted. The rack when it is fully mounted is fitted between these raised rails making it impossible for the rack to touch the roof of the car. See below directions.

Difficulty: Moderate

Instructions

Things You'll Need:

Tower
Crossbars
Self-sealing screws
Side rails
Drill

Step 1

Make sure the roof of your vehicle is clean and dry.
Step 2

Decide the type of roof rack that you'll need and that your car can support it.
Step 3

Get measurements

Measure the roof to determine the placement of your rack.
Step 4

Use a drill bit or drill stop to prevent over drilling into the roof of your car for attachments: towers or rack.
Step 5

After drilling the roof, attach all self-sealing screws to secure the rack to the roof. These screws have a seal underneath the screw head to prevent water leakage.
Step 6

Mount the towers to your side rails. Two on each side of the vehicle.
Step 7

The side rails have pre-drilled holes that are used as a template for drilling.
Step 8

Build the cross bars into the towers and secure with self-sealing screws.
Step 9

Install the vertical center roof protective slats; make sure that they are evenly placed.
Step 10

Luggage roof rack

Make sure that the rack is centered from side to side and that the measurements are even front to back.