Roof rack design questions.

[PRKXPAT]

Hello all!

My first real post here.

I have been on a many year hiatus from my project van. UJOR 8" kit 03 EB-350 Cargo 7.3. with 37 x 17
Its time to lay out my roof rack! I'm not sure if there is a "standard" or "ideal" cross rib spacing like 16" centers i.e. construction? I'm going/have all aluminum tube and 3" flat bar basically an Aluminess clone. Unfortunately I have nothing to physically compare OR measure. Any help, pictures, measurements would be awesome.
I have a tube bender and access to a plasma table and TIG, spool gun etc. Cant say I'm proficient though.

Thanks In advance.
PRKXPAT

[northleftcoast]

I have built several out of 1” sch 40 6063 pipe (1.3”+ OD). I use 1 x 1.5” 6061 rectangular tubing (.125 wall) for cross members on 16” centers. 3 or 4” x 3/16” flat 6061 bar makes good flooring slats.

The 6063 pipe bends easily for your corner radius and the 6061 rectangular tubing is much stiffer for your cross members. The joints weld easily if you create a good cope.

Make your own feet or weld a plate on the bottom and buy premade rain gutter mounts.

Tig will get you a better end product than mig but the wall thickness should allow either process. It’s a really good project to build skills. Aluminum is nice because you can leave it raw for a while to test it and make modifications before you commit to final powder coating.