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Old 06-09-07, 07:06 PM   #1
kjmillig
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Home built cartop rack

I'm copying this over from another thread:
I enjoy building all kinds of stuff, so when I started looking at cartop racks, I decided to build one. Now I'm almost ready to mount my 2x4 cartop bike rack. The rail is a 2x4x54" with a 7 1/2" crosspiece attached to one end with a lap joint. I then cut a channel in from the end opposite the crosspiece up 22", 3/4" deep, and 1 1/2" wide with a dato blade, smoothed the channel with a straight router bit, the half-rounded the edges with a router. I've mounted a Saris fork mount to the crosspiece after sanding and a double coat of flat black exterior paint. 3" stainless u-bolts will mount it to my factory luggage rack. I'll only be carrying one bike (mine), so I won't overload the factory rack.
I'll get some pics up as soon as I can. Has anyone else here built a rack before, cartop, hitch mount, etc?
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Old 06-09-07, 08:12 PM   #2
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Originally Posted by kjmillig
. I'll only be carrying one bike (mine), so I won't overload the factory rack.
So how does the factory rack attach to the car? I'm thinking the issue might be lift rather than weight capacity.
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Old 06-10-07, 07:13 AM   #3
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Channels are screwed to the roof. Crossmembers have a thumbscrew going into a square nut in the channel. Very typical factory installation. I made sure the channels were screwed, not just glued on.
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Old 06-10-07, 07:19 AM   #4
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Channels are screwed to the roof.
Screwed into sheetmetal. That's exactly what I'd be concerned about. Keep in mind that I'm a mechanic - not an engineer so I don't honestly know it that's going to be adequate or not.
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