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My DIY Roof Rack

Discussion in '2.5 Gen Tundras (2014-2021)' started by junior, Dec 10, 2020.

  1. Dec 10, 2020 at 6:12 PM
    #1
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Over the last couple of months, my brother and I designed roof racks for his Land Cruiser and my Tundra. I'm a software designer for a living and my brother is a mechanical engineer so its been fun to see our skills play out for different things.

    The result:
    Screen Shot 2020-12-11 at 10.22.49 AM.jpg


    The build:
    I've been calling it a "prinsu style rack" because we ended up taking inspiration and ideas from a bunch of different ones that are available. Our goal was to make something, maybe save on cost, but ultimately just enjoy the process.

    We started with a few basic measurements and cardboard mockups just to help guage the size and how it could look.

    Screen Shot 2020-12-10 at 5.50.41 PM.jpg
    Screen Shot 2020-12-10 at 5.51.07 PM.jpg
    ... my brothers was much more precise than mine.

    After we had the basic dimensions, I had fun with a few Photoshop mockups on my truck.

    upload_2020-12-10_17-56-2.jpg

    From there, I drew up a full size, rough design for the side rail in Adobe Illustrator.
    upload_2020-12-10_17-58-35.jpg

    I exported as a DXF for my brother, and he began to run strength calculations and the numbers for the actual thing which he made in Solidworks. If you want to use the design for your rack, or modify it, I have the DXF's uploaded here: https://app.box.com/s/7vvsy4vu8nsvtu4pa0vyyic8aivqw0xc

    So far, 2 other members have recreated the rack with the files above!

    We had a hard time figuring out the best and strongest way to mount the thing to both my truck and his at the right heights. The result ended up being pretty much the same for both of ours.

    13F01381-4C5A-4211-B72E-9452BB99829D_1_105_c.jpg

    After a few iterations we landed on a design we really liked. Using 1"x2" 8020 crossbars.
    AF83C26B-A0DA-4948-AD63-8F693494F8F6.jpg

    We started to add in a few little details to make it feel a bit more unique
    Screen Shot 2020-12-10 at 5.59.51 PM.jpg

    0053681E-62FC-4287-B7BC-9724FC2ACF39.jpg

    E9E742A1-B7D6-4224-A86D-809E78C0F9D8_4_5005_c.jpg

    And then we got them Laser cut. I chose 1/4" 6061 aluminum and my brother chose 3/16"
    12072E1E-C407-41C1-8FA4-DB3E74451A41_1_105_c.jpg

    B1FECFB9-2A3C-4108-8697-080A4884FE76_1_105_c.jpg

    Screen Shot 2020-12-10 at 6.06.10 PM.jpg

    We added a logo that I drew up for my brothers woodworking company, inspired by Kite Lake in Colorado.
    8E4079AD-9EC2-4352-8874-561B7E1AC714_1_105_c.jpg

    Then I got it all powdercoated at a local shop—Went with gloss black, I think I like it a lot!

    1525CC18-2642-4B7F-A5CF-DDE08180BD07_1_105_c.jpg

    295DE9BF-1E7A-454B-9A8D-432684CA9A50_1_105_c.jpg

    Sorry for so many pics, I wanted to show the whole process rather than just the results :thumbsup:
     
    Last edited: Dec 6, 2021
    lex2go, sonofdad, Luckydog and 43 others like this.
  2. Dec 10, 2020 at 6:13 PM
    #2
    YardBird

    YardBird Native San Diegan

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    Good job ! Thanks for sharing.
     
    junior[OP] likes this.
  3. Dec 10, 2020 at 6:14 PM
    #3
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Today I was able to begin getting it on my truck... one side at a time.

    B62DFD16-0995-458F-A61F-774CDEFBCB19_1_105_c.jpg

    64CD4C1F-D928-497C-BB96-861861A8C617_1_105_c.jpg

    My brother mocked his up on his truck before getting it powdercoated
    6768762C-BF15-4225-8856-80F9F8B5DE91_1_105_c.jpg
     
    Tundra'25, D4x4TRD, Orracle and 14 others like this.
  4. Dec 10, 2020 at 6:15 PM
    #4
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Thank you @YardBird!
     
    YardBird[QUOTED] likes this.
  5. Dec 10, 2020 at 6:17 PM
    #5
    RyRy12

    RyRy12 New Member

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    That’s awesome!! How much $ did the whole project come out to be? Any pics of it installed yet?

    edit: you posted more pictures in the time it took me to write a response. Sweet setup!!
     
    joseph_womack and junior[OP] like this.
  6. Dec 10, 2020 at 6:24 PM
    #6
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Thanks man! I'll get some better pics when I have time to finish installing it. The daylight hours are just so short right now.

    Our goal was to come out cheaper than purchasing one, and more or less we are at like ~$750... Things really just started to add up, specifically the 8020 crossbars and black oxide stainless steel hardware. I could have saved $ by painting it myself and not powdercoating it though... but since the cost has been spread apart it feels better than dropping it all at once haha :spending:
     
    D4x4TRD, zach_attack4, gosolo and 3 others like this.
  7. Dec 10, 2020 at 6:38 PM
    #7
    RyRy12

    RyRy12 New Member

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    Even if it wasn’t cheaper, just the process of making it your own would be worth it to me. I dig the one off stuff.
     
  8. Dec 10, 2020 at 6:40 PM
    #8
    The Patriot 1776

    The Patriot 1776 Asskick Fabrication: Shit Is Sick!

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    A bunch of us made our own similar ones on TW. I made 1 very similar to yours for ~$175. I don't how the hell you spent $750.
     
    junior[OP] likes this.
  9. Dec 10, 2020 at 6:52 PM
    #9
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Couldnt agree more. Been a fun learning process for me.

    Sounds like you guys did a good job! :thumbsup: I dont have access or a hook-up for the fab stuff, so the material and cutting for the rails and fairing cost about $300. I probably could have sacrificed on some things, but being the designer I am, I didn't want simple rounded corner rails that I could make with a grinder or something. For me personally, it wasnt intended to soley be a budget-focused project
     
  10. Dec 10, 2020 at 7:19 PM
    #10
    The Patriot 1776

    The Patriot 1776 Asskick Fabrication: Shit Is Sick!

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    We did all the work ourselves, or @ least most of us did. The rounded corners were easily done w/a jigsaw & the proper blade. It was surprisingly easy & turned out very precise. Very little was needed w/a grinder & flap disc to make it perfect.
    You have made a very nice product.
     
    joseph_womack likes this.
  11. Dec 10, 2020 at 7:25 PM
    #11
    TheBeast

    TheBeast The Beach

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    looks great ! fun project
     
  12. Dec 10, 2020 at 7:42 PM
    #12
    BTBAKER

    BTBAKER DIFFERENT NAME. SAME JUNK.

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    Very nice! Well done.
     
  13. Dec 10, 2020 at 7:46 PM
    #13
    TampaRD Pro

    TampaRD Pro Cunning Linguist

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    Lots.
    Very nice project. Nothing better than the satisfaction of having done it yourself. Congrats on the outcome!
     
  14. Dec 10, 2020 at 8:58 PM
    #14
    junior

    junior [OP] Member

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    Thats awesome. Sounds like it turned out great for what you needed., Do you have any pics of it?

    Thanks all. I agree, its hard to beat that feeling! It's on my mind to design a matching section for over the cab.. just gotta work up the confidence for the holes you gotta drill
     
    joseph_womack likes this.
  15. Dec 10, 2020 at 9:03 PM
    #15
    YotaBro

    YotaBro This forum will make me broke

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    Lots of shenanigans.
    Great job! Thanks for sharing!!
     
  16. Dec 11, 2020 at 6:08 AM
    #16
    Bammer

    Bammer I'm disinclined to acquiesce your request.

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    Excellent ! :cool:
     
  17. Dec 11, 2020 at 7:11 AM
    #17
    reneaux

    reneaux New Member

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    That's awesome man! Looks great, I have really been wanting to do something similar. Interested in sharing the DXF for it? I own a CNC table.
     
    junior[OP] likes this.
  18. Dec 11, 2020 at 10:30 AM
    #18
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Thanks everyone! Here's a few pictures of it fully assembled this morning. I'm really happy with how it turned out

    Screen Shot 2020-12-11 at 10.22.49 AM.jpg

    Screen Shot 2020-12-11 at 10.23.01 AM.jpg

    Screen Shot 2020-12-11 at 10.28.53 AM.jpg
     
    Last edited: Dec 11, 2020
    lex2go, Junior 88, pyrite808 and 14 others like this.
  19. Dec 11, 2020 at 10:31 AM
    #19
    junior

    junior [OP] Member

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    Black Rhino Rapid 17" 35x12.5 Mickey Thompson Baja Boss Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Dobinsons HD Leaf Springs Firestone Airbags + Daystar Cradles Leer 100XR Decked Drawers
    Definitely, a CNC table would be awesome to own. I have the DXF for the fairing and siderails here: https://app.box.com/s/7vvsy4vu8nsvtu4pa0vyyic8aivqw0xc

    I'll add it to my original post as well.
     
    rockmup likes this.
  20. Dec 11, 2020 at 10:56 AM
    #20
    Mgmtundra

    Mgmtundra MGM Crew

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    Well done the truck looks great.
     
    junior[OP] likes this.
  21. Dec 11, 2020 at 11:07 AM
    #21
    InTheRough

    InTheRough New Member

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    Excellent work! Congratulations on a successful design.

    I'm working on getting a CNC router table up and running to make cool things like this. I also use Adobe Illustrator and export to .DXF format.
     
    junior[OP] likes this.
  22. Dec 11, 2020 at 11:56 AM
    #22
    Sharpienads

    Sharpienads New Member

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    That is awesome. The whole truck is awesome, good job. I'm digging the wheels, are they just steelies with something in the center area?
     
    AggiePhil likes this.
  23. Dec 11, 2020 at 12:51 PM
    #23
    DIYDad

    DIYDad New Member

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    Nice work! I took the day off today to mess around with a DIY headache rack concept that has been rattling around in my head. I'm $150 into just on 8020 rails and shipping already. That stuff is super robust, but awfully pricey.
     
  24. Dec 11, 2020 at 1:07 PM
    #24
    21CGtundra

    21CGtundra New Member

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    What width did you use for the cross bars? The rack turned out great!

    *Side note, what wheels are those and tire size? Your truck looks awesome!
     
    AggiePhil likes this.
  25. Dec 11, 2020 at 1:19 PM
    #25
    BlackSheep

    BlackSheep caffeinated member

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    Way to go! Looks super sharp, OP. Time to do sliders, front and rear bumpers, skids...:D
     
  26. Dec 11, 2020 at 2:34 PM
    #26
    TONKA TUNDRA

    TONKA TUNDRA HULK SMASH!!

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    Awesome work! Rack and the overall truck look great! Little details like the logo make it really stand out and give it a nice finished look.

    Question on the mounting that would apply to any roof rack i guess.

    upload_2020-12-11_17-30-22.jpg

    Are these thru bolts with nuts on the inside of the camper? And did you use any sort of doubler on the inside to keep them from pulling back thru?

    I want to put some sort of rack on my LEER topper and curious as to how to mount it.
     
  27. Dec 11, 2020 at 3:51 PM
    #27
    junior

    junior [OP] Member

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    Thanks guys, the wheels are Black Rhino Grange with 295/70r18 ridge graps. The bars are 54", it seems just about perfect for the width of the cab as well. Just to the outer edge of the roof curve.

    Right? It adds up super quick but its pretty cool how there are so many mounting options and connectors for it. I know shipping got me too. Goodluck with your build!

    Gahhh you are right :spending:

    I wish I could answer your question better, but I ordered the Thule tracks installed from the factory. The mounts are connected using some weird slotnuts from Thule. From what I can tell, the tracks are bolted through the shell in 8 key areas where the its thicker on the very top (have you noticed the raised area on the inside roof?)
    upload_2020-12-11_15-53-9.jpg
     
    TONKA TUNDRA[QUOTED] likes this.
  28. Dec 11, 2020 at 4:23 PM
    #28
    AGuyFromNC

    AGuyFromNC New Member

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    Wow that turned out awesome.
     
  29. Dec 11, 2020 at 4:55 PM
    #29
    NoRcptn

    NoRcptn Better than mediocre poster

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    Very nice! Looks awesome.
     
  30. Dec 12, 2020 at 5:45 AM
    #30
    The Patriot 1776

    The Patriot 1776 Asskick Fabrication: Shit Is Sick!

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    Pics are somewhere here!
    https://www.tacomaworld.com/threads/diy-prinsu-style-shell-rack.521186/
     

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