So i've got a bunch of brackets I need to make for a van roof rack that will be made out of aluminium profile. The van doesn't have roof tracks so will need a bracket that can bolt through the factory roof bolting points rather than a T-nut type system.
The roof slopes down at the rear so will require a longer pair of brackets to make up the difference and keep the rack level. I've looked at the dimensions of a very expensive front runner roof rack that fits this van and am going to copy their foot design which is basically 5 pairs of 65mm high brackets and a pair of 90mm brackets at the back.
Really simple design - just an aluminium L bracket with some holes and slots:
Just trying to work out the easiest way to make this happen. No tig welder so cant think of a way to reinforce a folded piece of flat bar, so thought what if i buy some aluminium unequal angle that's the right size? I've found a website that does a pretty close size for the smaller 65mm ones (they do a 2.5 x 1.5 inch angle 1/4 inch thick which is 63.5 x 38.1 x 6.35mm). They can cut it to length so it works out if i go for a 75mm lengths for each bracket it'll cost £2 a piece which seems a nice easy option! Will just need to drill some holes.
Just wanted to ask if you think 1/4 inch thick aluminium will be up to the task? there will be solar panels on this roof rack and at times ill be walking around on it. I'm sure this fancy manufacturers brackets (pictured) are no thicker but they have got some gussets to stiffen them up.
The final point is I cant get angle in roughly the right size for the longer brackets. Closest I can find is 100 x 50mm so will need to trim 10mm or so off each side. I've got a grinder and a mitre saw that'll do metal so I'm sure I can work something out as its only 2 to make.
BTW I contacted the manufacturer about just buying the brackets and for all 12 they wanted £211 plus delivery...
Brackets when made up will get powdercoated and have some HDPE spacers underneath to avoid aluminium being clamped to steel.
Just wanted a sanity check that this is a good option really and I've not missed an obvious solution.
The roof slopes down at the rear so will require a longer pair of brackets to make up the difference and keep the rack level. I've looked at the dimensions of a very expensive front runner roof rack that fits this van and am going to copy their foot design which is basically 5 pairs of 65mm high brackets and a pair of 90mm brackets at the back.
Really simple design - just an aluminium L bracket with some holes and slots:
Just trying to work out the easiest way to make this happen. No tig welder so cant think of a way to reinforce a folded piece of flat bar, so thought what if i buy some aluminium unequal angle that's the right size? I've found a website that does a pretty close size for the smaller 65mm ones (they do a 2.5 x 1.5 inch angle 1/4 inch thick which is 63.5 x 38.1 x 6.35mm). They can cut it to length so it works out if i go for a 75mm lengths for each bracket it'll cost £2 a piece which seems a nice easy option! Will just need to drill some holes.
Just wanted to ask if you think 1/4 inch thick aluminium will be up to the task? there will be solar panels on this roof rack and at times ill be walking around on it. I'm sure this fancy manufacturers brackets (pictured) are no thicker but they have got some gussets to stiffen them up.
The final point is I cant get angle in roughly the right size for the longer brackets. Closest I can find is 100 x 50mm so will need to trim 10mm or so off each side. I've got a grinder and a mitre saw that'll do metal so I'm sure I can work something out as its only 2 to make.
BTW I contacted the manufacturer about just buying the brackets and for all 12 they wanted £211 plus delivery...
Brackets when made up will get powdercoated and have some HDPE spacers underneath to avoid aluminium being clamped to steel.
Just wanted a sanity check that this is a good option really and I've not missed an obvious solution.
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