Roof Rack options E350 RB

jso5000 · 05-26-2021, 10:27 AM

Hello fellow forum members,
Ive been wanting to pull the trigger on a roof rack.
Was going to buy from Ujoint in NC but it seems there is a
materials shortage or something and these are not available.
So I thought I would post to see what other options might be.
(Of course there is Aluminess.)
Im in Indiana and reasonably capable with welding. (Steel and Alum)
Roof rack to be used for solar, skybox, storage, flyrod holder, etc.

Interested in hearing what others have done for a rack

**daveb** · 05-26-2021, 03:28 PM

What type top do you have? Weight is the main concern with a manual Sportsmobile top operation. With their electric top I was told about 200 pounds is max but I made sure I didn't go past 175. I had Aluminess custom build my rack with smaller aluminum tubing to reduce weight.

jso5000 · 05-26-2021, 08:22 PM

I have the stock metal top.
No penthouse or fiberglass.
Would mount to gutter

NCMODELA · 05-27-2021, 07:28 AM

I used unistrut for mine. Custom built the whole thing. Was $600 or so to build.

The strut allows me to bolt anything to it and I have created a multilevel system for things

I tried posting the pic but it keeps coming in sideways ��*♂️

Twoxentrix · 05-27-2021, 07:40 AM

@NCMODELA, simple solution to having Pic’s show up in correct orientation = “Crop” them just a little first, then “SAVE”...now you can post and they will show up as you intended.

jso5000 · 05-27-2021, 08:04 AM

Unistrut is an interesting idea.
did you buy or make your gutter mounts?
what coating did you apply to the unistrut? (i think it comes galvi)

NCMODELA · 05-27-2021, 08:44 AM

It was a time consuming process. I used 1/4” 5x3 angle for the feet. Had to trim them to fit the gutter (middle ones are shorter, front ones curve). I made the gutter clamps out of 16 gauge but I think I’d buy them from summit if I did it again. I used 10’ and 20’ non slotted 14 gauge galvanized from an electrical supply store and just painted it. Most of the cost came from fasteners and unistrut flat and corner brackets.

If you are interested just send me a pm. I am in Nashville TN.

86Scotty · 05-27-2021, 01:24 PM

There are lots of homebrew roof racks on the Expedition Portal 2/4 wd vans forum. You'll have to dig a bit probably but lots more home builds and home builders than here.

Also, I'm sure if I think on it awhile some specific ones will come to mind.

jso5000 · 05-27-2021, 02:05 PM

ok will give it a look
thanks.
I have been looking at 80/20 aluminum extrusions too.
May just have to make my own corners cause I like the rounded look

Obes · 06-03-2021, 11:46 AM

I made my corners for using 10 series (1" x 2") extruded aluminum. I did them as a segmented 90 so I can mount angled down lights on all the corners. I ordered t-slotz smooth black, my rack is 12 ft long (e350 eb). I like how modular t-slot is for mounting things and making changes. Check out t-slotz to see what inventory they have. They were reasonably priced and good on freight since I had to ship 138" bars.