Second Gen Roof Rack

[Deepfry]

So the other day I finally finished building my rolling welder table and I figured that I need to get going on all the projects that Ford forgot to put on the second gens: racks, sliders, decent bumpers, tow points, ect. So I went to my local iron works with cash in hand and gave the owner 75 bucks and walked out with 6 3/4"x1/8"x 12' sticks of box, 12' of 6"x1/8" plate and 10' of 1/2"x1/8" box. a week later I ended up with a decent looking roof rack that can hold my fat ass and some off road lighting for those midnight runs in the woods, and this is the end result, enjoy:

 

[gmanpaint]

Sweet! Looks great

How many watts are those rear LED's?

Did you bolt into the roof or just use the stock sliders in the tracks?

Wish mine was that nice!

 

[Deepfry]

rear LEDs are 27 watts and throw a ton of light. i use the same ones for my fogs. They are Grote Trilliants. I used a piece of 3/4"x3/16" plate to mount to the existing track on the roof. all stainless hardwear.

 

[Torqueranger]

I like and I was thinking about building one but have no real use for it lol....

 

[Deepfry]

Me either, I only built it out of boredom and a need for something to hold my lights lol

 

[Torqueranger]

Me either, I only built it out of boredom and a need for something to hold my lights lol

Well i work 60 to 70 hours a week and my old lady drives my truck while i am work....

 

[FU MONSTER]

Looks great!

 

[xshift28x]

Got any dimensions on it length x width x height and how did you bend the 90's in the square tubing?

 

[Deepfry]

Tubing is 3/4" box 16 ga. Flat stock is 6 x 1/8". Rack Dimensions are 56" long x 34" wide x 7 1/2" tall. The rack is the same dimensions as the factory rack tracks. I mounted it to the track by using a strip of 1" x 1/8" flat stock so it could slide into the track. I drilled and tapped some 1/4 20 holes and used stainless cap screws from home cheapo to mount it. As it stands it will support my fat ass (265lbs) without flexing. All the wiring is run inside some 1/4" box tubing to hide and protect it and I used some marine plugs to make it removable (so I can pass NJ inspection). to make the bends I made a jig out of 1" plywood and bent it around the plywood. No heat needed. I believe I used a 1 gallon spackle bucket as a template for the jig. Any tighter bend and the tubing would have creased. All in all I have about 120$ worth of material that I used to make the rack (not including lights, wiring, plugs). I painted it all with 2 coats of self etching primer and 4 coats of Rustoleum Hammertone paint. Hope this helps. Any other questions, feel free to ask!