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zj95maxx
01-24-2009, 07:36 PM
My brother wanted me to build him a roof rack for his 05 Xterra. He bought me a 1" die and let me and my friend go to town building it.
The actual "xterra" cut out bracket was not made by us, some other guy made that.

Rackless
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0189.jpg

Sanding down some 2" flat stock to run overtop the Brackets that are bolted to the roof.
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0188.jpg
Drilling holes
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0190.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0191.jpg

First hoop
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0192.jpg

The tube runs on the outside of the 1/4 plate, so we stitch welded the tube to the 1/4
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0193.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0194.jpg

http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0195.jpg

Supports to be notched
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0196.jpg

notch notch notch
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0197.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0198.jpg

Since the tube runs on the outside of the 1/4, making crossbars that are even with the tube were a bit tricky, we decided to cut the end out like this, it fits on the tube hoop and welds to the 1/4". Should be plenty strong
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0199.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0200.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0201.jpg

Supports and second hoop
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0202.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0203.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0204.jpg

Second crossbar
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0205.jpg

The very front crossbar isnt cut, and is just simply notched, but it is pushed against the 1/4 to run a bead across
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0206.jpg

Third crossbar
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0207.jpg

Done for the night...Finishing the front up tomorrow.

This is the general outcome we are shooting for.
http://www.gobinissan.com/Images/07-Ranger-Rack.jpg
The front will bend down like in the picture

Mesh will be plating the bottom if I have time....

What ya think?

Jeeperoni91
01-24-2009, 09:00 PM
holding a 3" piece of tube while you grind it can't be safe, even with welding gloves on

zj95maxx
01-24-2009, 09:13 PM
Jokes on you, those are 2 1/2 inch pieces :rolleyes:

CrawlerReady
01-25-2009, 04:19 PM
holding a 3" piece of tube while you grind it can't be safe, even with welding gloves on

I'm pretty sure most of us have done that, can't say that I haven't :smt038

Of course IIRC, Maxx likes to also weld and work in his flip-flops....:smt104

BTW, looks good so far!

paulkeith
01-25-2009, 04:59 PM
you kids are like the poster children of how to not work safely.


good luck with the rack. looks good so far.

zj95maxx
01-25-2009, 06:47 PM
Front support
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0210.jpg

Front lower hoop
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0211.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0212.jpg

Slanted bars
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0213.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0214.jpg

How the front is getting support
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0215.jpg

http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0216.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0217.jpg

forward hoop
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0218.jpg

Light tabs
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0219.jpg

Dont have time to do the mesh but here are the angle iron support that the mesh will get tacked to.
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0220.jpg

Done
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0222.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0221.jpg
http://i203.photobucket.com/albums/aa45/zj95maxx/rack%20build/100_0223.jpg

Jeeperoni91
01-25-2009, 07:36 PM
hahahahahahahhahahahahaa fuzzy's jeep is still taped off, but not cut up yet.