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?
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?