[jurgen10]

Pajer Gen2 Roofrack DIY.

So I decided to build my own roof rack after some searching on the net and coming to a conclusion that I will never have enough money to buy all the toys that I want...so I have to build my own (with the help of my father-in-l.a.w. who is a magician with a welder)
I started of with some measurements of the roof and gutters of the car:

Drawings.jpg (13.21 KiB) Viewed 1987 times

We decided to use 50mm mild steel pipe as the main frame for the rack.
The pipes were taken to a local exhaust shop for 90 degree bends two section of 3m pipe was used and then joined with a internal support in the centre of the rack.

Once the frame was complete it was just a question of welding on the feet and the supports for the slats.
The feet where made using 50mm flat bar, and 25x25 angle iron was used as the supports for the meranti slats. These would probably be replaced with aluminium in due course.

Now all that was left to do was prime, paint and fitment.

There is very little wind noise when driving with the rack empty because of the round shape and the slats that are in line with the direction of travel.

[macjohnw]

Nice one!

[4ePajero]

It is a very neat design.
I have two problems with the mild steel though

• rust
• weight

Did you weigh the rack?

[jurgen10]

No never weighed the rack, but it is light enough to be removed by two (one on each side)

Rust - Yes, but not a big issue for us living in the north, and the government solved this problem by increasing the fuel price to such an extent that I can only afford to drive to the ocean once every two years....

But I agree I have to powder coat it.

The rack is strong enough for a minimum of 200kg ( as tested) but I would not recommend to load that kind of weight so high...makes for interesting driving...