Ok, I've had the XJ for over a year now and it's time for a roof rack. I hope to complete in the next month and this will be my build thread. I'm in the design process now.

I found this picture is the closest to what I have fabbed up in my head. 3/4" square stock with approximate dimensions 4' x 5'. I may stretch it to 6' though.



I want the roof rack for:

• Getting the spare out of the cargo area.
• CB and Ham radio antenna mounts.
• Mounting lights pointing forward. (Maybe some rearward pointing lights.)
• Mounting HighLift, shovel, axe, etc.
• Gas cans, water, camping supplies on longer trips.
• Possibly some bike mounts.
• ???

I plan to remove the stock rails and fab up some brackets to use the same holes/locations. Kind of like the brackets and mounting Michael did on his X rack.



The first rack pictured above seems to have good bottom crossmembers, but I was also considering doing a sheet of mesh like Michael's rack. Any pros or cons of either?

The other feature of Michael's rack I liked is how the front bumped up to allow for lights. My roof is flat though. How would you guys design the front of my rack to do the same? I want the lights inside the rack so tree branches won't tear them off. Same thing for the CB and Ham antennas. The top of the antenna is flexible, but the base would be somewhat protected by the rack.

Here we go...

PS. Michael, I think you have a really nice rack.

Thanks :cool)
Don't know how for sure you'd do the light protection with square stock and make it look good.

I do know two things about mine

1. My lights would not still be up there without the way we set it up to get the limbs up and over.
2. I would put a floor in it hands down. I've ridden, collected firewood, and put garbage bags up there without any worry.

Skatchkins wrote:I would put a floor in it hands down. I've ridden, collected firewood, and put garbage bags up there without any worry.

If I did a mesh floor, would I need as many crossmembers as the first rack shows or could I cut a couple of those out?

Just use the short horizontal ones

I like that kind of front view, but don't know how to make it look best from the side. See the ??? marks.

How tall are your lights? Why not make the sides taller? My $.02

KE7NEG wrote:How tall are your lights? Why not make the sides taller? My $.02

I think the rectangle lights I'm going to use are only about 5 inches tall and was planning on making the rack 6 inches tall. That's probably doable.

I also thought about it much harder last night and realized the part in my new drawing below identified in red will be angled where it sticks above the rack. If I don't make the rack taller as you suggest, I think I'll just do it like the new picture.

Design phase complete.

Removed my transfercase skid plate tonight in prep for mounting the rock sliders. I think I'm going to have to notch out part of where it mounts because in conflicts with the rock slider mounting point. Ugh.

Then, I removed the stock roof rack. The rails measured about 47-48" wide and only measured about 52" long. That is smaller than what I thought it was. I'm going to stick with making my new rack 48" wide and decided it's going to be 60-64" long.

Cool.
How long before you need new tires?

Lookin' good, man! Once you work out the design to cover the lights, I'll need to cut my rack up and modify it to be more like Mikes (have I also mentioned lately that I'm fixated with Mike Magnificent Rack?)

speaking of Mike's Magnificent Rack... has anyone seen the surgeon who did his work, lately? Dr. Geoff? Is he still practicing?

Skatchkins wrote:How long before you need new tires?

Definately on the wish list. I don't have the ~$800 right now. I want some of those BFG KM2's.

alanzona wrote:Lookin' good, man! Once you work out the design to cover the lights, I'll need to cut my rack up and modify it to be more like Mikes (have I also mentioned lately that I'm fixated with Mike Magnificent Rack?)

speaking of Mike's Magnificent Rack... has anyone seen the surgeon who did his work, lately? Dr. Geoff? Is he still practicing?

Ha
I believe Dr Geoff's been working on Yellowsub's front tube fenders :cool)

Skatchkins wrote:Ha
I believe Dr Geoff's been working on Yellowsub's front tube fenders :cool)

Psst... Dr.Geoff has been in surgery since Last Sat on his own. ;)

Drove over to BGB Steel on my lunch break.

Quote on material:
70 ft. 3/4" square tube = $70
10 ft. 1 1/2" flat stock = $7 (or 20 ft. = $12)
4'x8' sheet of flat 3/4" mesh for floor = $63

He said standard 3/4" square is 16 guage. He can also get 14 guage. Should I upgrade to the thicker stuff or is 16 guage strong enough?

I can jump up and down on my 16 guage.

Skatchkins wrote:I can jump up and down on my 16 guage.

that's illegal in 27 states, you know.

I used 16ga on mine, holds up fine :)g)

Thanks guys. Also confirmed with Dave and he says 16 guage too. I just wanted to be able to tell people "I can jump up and down on my 14 guage."

Rock sliders installed - Finally!!! Aquired Dec. 7, 2008. Ugh. Roof rack project needs a kick in the butt.

Woo hoo.