Ok guys, I've been wanting to do this project for a long time now and I've tried a lot of avenues but never seen them all the way through. I want to build a light rack like this SEMA vehicle, not with the snowboard attachments but the basic set up like this, more for carrying kayaks and other things. I wanted to know what material you guys would use, I want to keep the cost to a minimum cause the lights I want to run are going to cost a fortune. I have access to a pipe bender but just didn't know what to start with and it can't be too heavy.

 

Ok first off the rest of the truck is ugly as hell IMO Anyways I would start with some aluminum and TIG it also use a mandrel bender for quality bends and also for the front mounts make sure to put rubber pads in between that and the roof. Then just bolt the front down to the roof with a large washer on the bottom. It will require 2 holes through your roof. Maybe like 1/2" bolts just pick up some grade 8's they are cheap and worth it.

 

MmMmM I want that snowboard rack

 

Yeah I agree, I hate the color, but I love the rack. Especially how it ties in with the running bars and the bull bar....never been a big fan of the bull bar but with this set-up I like it.

 

....and it gives me an excuse to put my running bar back on

 

it IS a truck. throw em in the bed. Racks are for SUV's

 

Now let me see if I get this right. The front of the rack is bolted to the cab roof. It looks like the rear of the rack is bolted to a bed mounted roll bar. I don't think I would be welding those front to back bars on as there will be considerable movement between the front and rear. The bed is bolted to the frame and the cab is rubber mounted on the frame and designed to move some. Yea, it looks cool, but I just don't think it will last long on a real vehicle. There is too much movement there. The front to rear bars would need to be suspended at the bed mount to allow proper movement. Am I missing something here?

 

I think that is a very good point. The cab is going to move in comparison to the bed. You could always rigid mount he cab.

For materials, I'd use some chrome moly roll cage tubing. After is all lined up and ready to go have it ceramic coated. You could go almost chrome shiney or semi-flat black coatings.

 

I have to agree with you. That light bar is exactly what I'm looking for. I am trying to get roof racks right now and possibly the cargo basket, but want the light bar on the front of it. I think it will look good with a brush guard I"m getting as well....aslo with a couple of lights on it. Let me know how you decide to do it cause I may try to steal some ideas off of you.

 

I guess you've never been kayaking they are almost as long as my truck and I need the bed for camping gear, plus I want the added lights.



And I noticed what you guys are saying about the bed movement in conjuction with the cab....I didn't understand it either cause I've seen this truck in action and thought the bed would rip the rack away from the roof when offroad, but it didn't

Where could I find some of that chrome moly roll cage tubing?

 

anyone???

 

There are lots of online retailers that sell DOM tubing. I think "roll cage" tubing would be much thicker than you really need. It is usually about .08-.1" wall thickness.

Looks like the rack on that truck is 3-4" in diameter.
Check out McMaster Carr or metalsdepot.com they should carry it.
I would get some thin wall 3.5". It wont take much to support the weight of a couple lights any kayaks. Of course you will need access to a mandrel bender, tubing notcher and welder.

If you "fix" it to the roof, you could run it into the stake pockets on the bed. Just weld a square adapter so it sits in the stake pocket and is not bolted in. That should allow some movement between the cab and bed.

Good luck and post some progress pics. It will be bad *** especially if you put Lightforce lights on it like the truck you posted!

 

Looks sort of like the roof rack on the old Nissan Frontier Crew Cab.

 

tycoz, if you figure this out and make one let me know how it was/how much it cost...i'd really like to get my hands on a black one haha

 

In addition to what JMB said, your local steel mill or depot can provide the steel you want. Chrome moly is the more expensive stuff. Its lighter because its thinner and stronger than mild steel. Mild steel would be ok. "Blue line" tubing would work fine and its a little cheaper. It has a blue seam down one side of the tube and that is what my roll bar tubing is actually made from.

The steel is usually sold in long lengths, so you will need a trailer to haul.

Hopefully you have some fabrication skills or this project is going to get very expensive.