double cab roofracks project

I took measurement about 1yr ago, but havent found the time to realy put into this until now.
Of all the racks out there, i really liked this style, so i went in that direction. One thing i wanted to improve was the construction. Instead of having the mounting tabs off the aluminum (which leaverage like 3" in and arent gusseted), im using a 1x1 steel angle to run the entire length on the inside of the plate, and have steel tabs welded along with an inner gusset.
Been through like 5iterations of minor changes trying to match the roofline how i like, very close to a final cut from .188aluminum.
What do you guys think?

 

Minor but will make the cab rack install easier later, my roof light will just plug in. May downsize the plastic sheild or run like 4ft of shrink wrap down the length.

The A-pillar windsheild trim is just 4 screws, peel away the weather stripping to see(easy to put back). Inside the trim theres a decent gap to stuff a wire (12ga in my case). I drilled 2 holes to run a zip tie thru, 5 total with even spacing. Just need to cut like half in off the end of the rubber at the top for the wires to poke through. Might dab some silocon to fill it back in. Ill get an installed pic later. Dark outside.

 

Very cool. I'm excited to see the final version. Those sliders look beefy also!

 

Looks good, I like it

 

I forgot to add a closer up pic.
We use this crap wood panel as waste backerboard material at the shop. Very useful to also use it for proto work instead of cutting to metal first go. I added slotted slides to adjust height for mockup, and theyre incremented with notches to reference. Happy with the gap it has, around 5/8". Less looks funny, too much gap looks funny also. This roofline was hard to profile! Seems easy like take depth measurements and fit a curve, but the roof and doorlines are a little different, so theres a visual aspect of it being different from the measurements and when you physically stand there to look at it.

 

I really dig this! If you decide to sell these, I'd be in for a cap rack.

 

Looks good. I actually started messing with some rack designs in SW a few months back. Kinda waiting for my works laser to get installed before getting too serious.
Keep it up!

 

I'm digging this a lot. How's it mount to the cab?

 

Think it looks awesome!

 

Rad! Nice job so far.

 

Thanks guys! Its exciting to see it come together.

Im mounting them with 3/8-16 thread-serts, ive read the rain gutters are 4 overlapped sheetmetals adding up to about 0.25thick. Hesitant to drill into a perfectly nice cab haha. And ill just gap out of the rain gutters with some 3/4" spacers or so.
Ive used these same threadserts for mounting lightbar brackets before and no issues.

The big reason i want to do all this is i have a solar setup to run on the shell, but need a rack to mount stuff to.
Cab rack will get built but wait to install. Just wanted to make sure i can mount the shell rack dead even with the cab rack physically there to reference, so that when the cab rack goes on, should be no worries.

Solar is 100w panel, pwm charge controller, 100AmpHr agm batt, and thats powering an inverter, a 12v water punp for a 10gal tank, fans, lights, and theres a 6gang switchboard on breakers for all the 12v stuff.
Desert trips will be great this season!