$30 cheap bastard roof rack

[timb.]

adapt it over to xterras

http://forum.planetisuzoo.com/viewto...f+rack#p570971

[SnickerDoodle]

It does look quite weak. I think it would look better if it was made using a thicker conduit.

[midget28]

You could make something alot better for cheaper.

I started too once then halfway through I thought about how little it would actually get used & decided i could think of better places to hang 100lbs of crap.

[intender]

I am actually about 90% of the way done building a rack out of 3/4 conduit. I havnt posted it in my build thread yet because I have been working on it slowly for about a year when I have time. Also I have been using my small wire welder to weld instead of screwing it together. I actually tapered mine towards the front a little. I want to say is about 2 inches less wide in the front than in the back where the tire goes. All in all I would say the thing is pretty strong. I weigh right at 250lbs and have stood mine up on the back side and jumped up and down around my driveway like a pogo stick and it didnt budge.

for the spots where I had to couple the sections of emt together instead of putting them on the outside and using 3/4 couplers I bought some 1/2 couplers removed the screws and then ground the area down where the screws went smooth. with a little bit of force you can push the coupler inside the 3/4 and then slide the other side over it as flush as possible. Then weld and grind smooth.

Word of advice to anybody that might decide to weld emt. first off it is a pain to weld. low and slow or you will burn holes all in it. second it is galvanized, so be careful. only do it outdoors if possible and avoid the fumes like the plague. It probably wont kill you if you breath in too much of the fumes but it will sure as heck make you sick as a dog. Learned that my first time around. After that I would only weld outside and then for about 20-30 minutes max before I took at least a 30 minute break. havnt been sick from it since then.

[midget28]

Welding galavanized is a bad idea should just get some small tubing you can pick up from about any tractor supply store.

[intender]

Originally Posted by midget28

Welding galavanized is a bad idea should just get some small tubing you can pick up from about any tractor supply store.

I agree. I had a bunch of emt left over from a job I did so I just kinda started going to town. I probably had about 80 percent of the pipe bent the first day. The second day I welded up about 60%. The 3rd day I was sick as a dog. It was almost like having a bad hangover. I just assumed I was sick and took a couple of days off. that weekend I went back at it and finished all but 2 of the pipes between the top and bottom. that night and all day the next day I was sick as a dog again. since then I have spent the rest of the time grinding it down and and touching up some welds. I hate grinding so usually after about 20 minutes I get fed up and dont mess with it for a couple of weeks.

If i had to do it all over again I would have went with some 1/2" rigid since I have a pipe bender for that or just not messed with it at all. Still I probably only have about $20 in it.

[cbxterra]

the problem with welding galvanized is the coating. The zinc off gasses which isn't good for you at all. I learned the hard way welding patches on an old truck years ago. One tip if you really have to use coated - grind off the coating where you're welding. that way you don't get the zinc to breathe [much better for your lungs/body] but yeah like a lot will recommend- don't weld coated steel. that's also why you burn through so quick the zinc causes a reaction in the steel. you think emt is bad, try zinc coated sheet metal. works like a plasma cutter