1. Welcome to Tundras.com!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tundra discussion topics
    • Transfer over your build thread from a different forum to this one
    • Communicate privately with other Tundra owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

My DIY Roof Rack

Discussion in '3rd Gen Tundras (2014-2021)' started by junior, Dec 10, 2020.

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

    junior [OP] Member

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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

    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 11, 2020
  2. Dec 10, 2020 at 6:13 PM
    #2
    YardBird

    YardBird Native San Diegan

    Joined:
    Jan 15, 2019
    Member:
    #24572
    Messages:
    9,293
    Gender:
    Male
    First Name:
    Jonesy
    San Diego
    Vehicle:
    2005 RCLB
    American Thunder Cat Back ~ Retrax Pro ~ Toyota Bed Mat ~ OEM Split Spoke Wheels
    Good job ! Thanks for sharing.
     
    junior [OP] likes this.
  3. Dec 10, 2020 at 6:14 PM
    #3
    junior

    junior [OP] Member

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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
     
    judsonpreuss, gosolo, JRock and 11 others like this.
  4. Dec 10, 2020 at 6:15 PM
    #4
    junior

    junior [OP] Member

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    Thank you @YardBird!
     
    YardBird likes this.
  5. Dec 10, 2020 at 6:17 PM
    #5
    RyRy12

    RyRy12 New Member

    Joined:
    Apr 28, 2020
    Member:
    #45657
    Messages:
    76
    Gender:
    Male
    Vehicle:
    ‘17 Silver SR5
    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

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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:
     
  7. Dec 10, 2020 at 6:38 PM
    #7
    RyRy12

    RyRy12 New Member

    Joined:
    Apr 28, 2020
    Member:
    #45657
    Messages:
    76
    Gender:
    Male
    Vehicle:
    ‘17 Silver SR5
    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.
     
    junior [OP] likes this.
  8. Dec 10, 2020 at 6:40 PM
    #8
    The Patriot 1776

    The Patriot 1776 Asskick Fabrication: Shit Is Sick!

    Joined:
    Aug 25, 2020
    Member:
    #51316
    Messages:
    576
    Gender:
    Male
    Great State Of TEXAS
    Vehicle:
    '16 TSS CM 4x4
    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

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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!

    Joined:
    Aug 25, 2020
    Member:
    #51316
    Messages:
    576
    Gender:
    Male
    Great State Of TEXAS
    Vehicle:
    '16 TSS CM 4x4
    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

    Joined:
    Apr 27, 2016
    Member:
    #3246
    Messages:
    11,600
    Gender:
    Male
    SoCal
    Vehicle:
    2012
    looks great ! fun project
     
  12. Dec 10, 2020 at 7:42 PM
    #12
    BTBAKER

    BTBAKER HOW CAN I GET RID OF MY NEW MEMBER STATUS?

    Joined:
    Nov 26, 2017
    Member:
    #11185
    Messages:
    4,210
    Gender:
    Male
    First Name:
    Brad
    Castle Rock
    Vehicle:
    2017 Tundra Limited
    Very nice! Well done.
     
  13. Dec 10, 2020 at 7:46 PM
    #13
    TampaRD Pro

    TampaRD Pro Cunning Linguist

    Joined:
    Dec 23, 2019
    Member:
    #40248
    Messages:
    123
    Gender:
    Male
    First Name:
    Stanley
    Vehicle:
    2020 MGM CM TRD Pro
    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

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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

    Joined:
    Sep 13, 2020
    Member:
    #52176
    Messages:
    570
    Gender:
    Male
    First Name:
    Calvin
    FL
    Vehicle:
    2017 Cement Grey Tundra TRD PRO
    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.

    Joined:
    May 23, 2019
    Member:
    #30901
    Messages:
    463
    Gender:
    Male
    First Name:
    John
    SW CT
    Vehicle:
    2019 Tundra SR5 TRD Crew Max 4x4
    Excellent ! :cool:
     
  17. Dec 11, 2020 at 7:11 AM
    #17
    reneaux

    reneaux New Member

    Joined:
    Jan 14, 2020
    Member:
    #41189
    Messages:
    220
    Gender:
    Male
    Houston, TX
    Vehicle:
    2014 TSS SR5 DC 4x4
    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

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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
  19. Dec 11, 2020 at 10:31 AM
    #19
    junior

    junior [OP] Member

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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.
     
  20. Dec 11, 2020 at 10:56 AM
    #20
    Mgmtundra

    Mgmtundra New Member

    Joined:
    Oct 1, 2018
    Member:
    #20047
    Messages:
    115
    Gender:
    Male
    Well done the truck looks great.
     
    junior [OP] likes this.
  21. Dec 11, 2020 at 11:07 AM
    #21
    InTheRough

    InTheRough New Member

    Joined:
    Nov 16, 2019
    Member:
    #38737
    Messages:
    302
    Gender:
    Male
    First Name:
    Kolt
    Gig Harbor, Washington
    Vehicle:
    2020 Platinum
    AR Headers DirtyDeeds Exhaust UpTop Cab Rack Forged Rock Warrior wheels
    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

    Joined:
    Aug 14, 2018
    Member:
    #18151
    Messages:
    225
    Gender:
    Male
    Vehicle:
    2018 Tundra SR5 TRD O/R
    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?
     
  23. Dec 11, 2020 at 12:51 PM
    #23
    DIYDad

    DIYDad New Member

    Joined:
    Mar 10, 2020
    Member:
    #43766
    Messages:
    337
    Gender:
    Male
    Vehicle:
    2020 Tundra 1794
    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

    Joined:
    Oct 23, 2020
    Member:
    #53986
    Messages:
    1
    Vehicle:
    2021 Cement Grey Tundra SR5
    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!
     
  25. Dec 11, 2020 at 1:19 PM
    #25
    BlackSheep

    BlackSheep falling uphill

    Joined:
    Aug 21, 2018
    Member:
    #18406
    Messages:
    809
    Gender:
    Male
    First Name:
    Scott
    Kansas City, MO
    Vehicle:
    2010 BLK Rock Warrior Dbl Cab
    a random assortment of mods
    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!!

    Joined:
    Jan 15, 2020
    Member:
    #41252
    Messages:
    74
    Gender:
    Male
    KY
    Vehicle:
    2014 DC Magnetic Grey
    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

    Joined:
    Nov 14, 2018
    Member:
    #21726
    Messages:
    270
    Gender:
    Male
    First Name:
    Zach
    Half Moon Bay, CA
    Vehicle:
    2016 Tundra TRD Off Road
    Black Rhino Grange 18x9 +12 Ridge Grappler 295/70/r18 Bilstein 6112 at 2.5" w/ 1 Coach Builder Shim on each side JBA UCAs Bilstein 5160 Coachbuilder +3 Shackles Firestone Airbags + Daystar Cradles Leer 100XR DIY Roof Rack
    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 likes this.
  28. Dec 11, 2020 at 4:23 PM
    #28
    AGuyFromNC

    AGuyFromNC New Member

    Joined:
    Oct 11, 2020
    Member:
    #53444
    Messages:
    43
    First Name:
    Nick
    Vehicle:
    2020 Tundra CM TRD Offroad
    Wow that turned out awesome.
     
  29. Dec 11, 2020 at 4:55 PM
    #29
    NoRcptn

    NoRcptn Mediocre Poster

    Joined:
    Sep 17, 2018
    Member:
    #19520
    Messages:
    792
    Gender:
    Male
    NorCal
    Vehicle:
    2017 Platty crewmax
    A.R.E. CX HD, SwitchPro9100, ARB compressor, Firestone RideRite F3 Wireless airbags, Method w/305's
    Very nice! Looks awesome.
     
  30. Dec 12, 2020 at 5:45 AM
    #30
    The Patriot 1776

    The Patriot 1776 Asskick Fabrication: Shit Is Sick!

    Joined:
    Aug 25, 2020
    Member:
    #51316
    Messages:
    576
    Gender:
    Male
    Great State Of TEXAS
    Vehicle:
    '16 TSS CM 4x4
    Pics are somewhere here!
    https://www.tacomaworld.com/threads/diy-prinsu-style-shell-rack.521186/
     

Products Discussed in

To Top