How to make an expedition car rack yourself. Do-it-yourself car roof rack: a cozy nest for your things Do-it-yourself car roof rack

One of the most common problems for motorists is the lack of free space for transporting large or bulky cargo. To remedy this shortcoming, some manufacturers equip cars with additional roof racks. And those drivers whose car is not equipped with a roof rack can make and install it themselves. But in order for the result to meet all expectations, it is important to understand how and from what to make the structure.

The roof rack, located on the roof of the car, is designed to carry bulky goods that, for various reasons, do not fit into a standard trunk. Very often, on the roof of a car, the driver is asked to transport bicycles, bulky suitcases, fishing tackle, and even building materials that are long in length, such as boards or skirting boards.

Not all owners need to install a roof rack. A clear need to install additional luggage space arises in such cases:

• Frequent journeys, long trips and travel "savage", involving the use of large travel devices and furniture;
• Engaging in active sports and recreation;
• Regular carpentry or renovation work.

A trailer can act as an alternative to the roof rack. However, to use it, certain driving skills and the mobile structure itself are required. Therefore, it is easier to use a roof rack.

There is no need to install a roof rack on a car if the car is used by the owner exclusively for movement.

Preparatory moments

Before starting the manufacture and installation of a trunk with his own hands on the roof of a car, it is important for the owner to complete a number of preparatory work. These include:

• Selection of the most suitable type of construction;
• The choice of the main material from which the trunk will be assembled;
• Selection of the type of fastening that will be used for mounting the finished structure on the roof.

The final result of the work directly depends on the thoroughness of these activities.

Selecting the type of construction

Car roof racks are of two types:

• Lattice, or arcs-crossbars;
• Boxes.

Crossbars allow you to transport loads of various sizes on the roof of the car. In addition, such a design is easy to make yourself. Trunk boxes, although they have a more attractive appearance, are notable for their small capacity. In addition, it is extremely difficult and very costly to make boxes on your own.

That is why, when considering the options for the independent manufacture of roof racks for a car, it is best to opt for lattice structures such as an arc-cross member.

Material selection

When planning to assemble and install a homemade roof rack, it is very important to choose the most suitable material for the design. It should be borne in mind that the weight of the product can negatively affect the speed and maneuverability of the machine, as well as fuel consumption, significantly increasing it. Therefore, do not use heavy materials.

Light and soft metal alloys are the optimal material options for the trunk. Aluminum is ideal for these purposes, which also has protection against corrosion processes. However, this type of trunk will not come cheap. In order to significantly save money and get a good result of the work, profile thin-walled pipes can be used as a material.

Determining the type of attachment

Mounting a homemade roof rack on a car roof can be done in the following ways:

1. Regular installation. It can be produced when the manufacturer has provided special mounting holes in the roof of the vehicle. In this case, the luggage compartment is fixed by bolting it to the body at several points along the perimeter.
2. Universal installation. It is carried out by installing special fasteners in the holes of the gutters.
3. Installation on roof rails. These structural elements are longitudinal side rails located on the roof of the machine.

The most convenient and gentle way for the car to fix the trunk is to install it on the roof rails. These items are usually made of plastic.

Manufacturing technology

In order to quickly, correctly and efficiently make a roof rack on a car roof with your own hands, it is important to carry out the work in the following sequence:

1. Prepare all the necessary materials and tools.
2. Draw up a drawing of the future structure, as well as the principle of its installation.
3. Make a trunk according to measurements and a developed design drawing.
4. Fix the finished roof rack using the selected method.

Before starting work, it is important to measure the roof of the car, on which the trunk will be installed. And when developing a drawing of a future trunk, take into account not only this, but also the geometry of the roof.

Required tools and materials

The main part, which cannot be dispensed with in the process of making a trunk, is a suitable metal. Also, in the process of work, the following components and accessories will come in handy:

• Welding machine;
• Grinder with attachments for metal cutting;
• Polyurethane foam;
• Clamps for car mufflers;
• A set of grinding tools;
• Fiberglass with a density of at least 300 g / m 2.

For the final stage of creating the trunk and ensuring its long-term operation, car paint will be required. The color of the paint can be any. However, the trunks that look best on the car are painted in the tone of the car body, as well as in silver or black.

Drawing

To create a drawing of the future trunk, you need to make a number of measurements:

• Measure the distance between the existing rails;
• Calculate the length of the roof and determine the dimensions of the indents from the edge.

Taking into account the weight of the metal components and the required load capacity of the trunk, it calculates the required amount of material, and also schematically depicts the appearance of the future structure.

After carrying out all the calculations, it is necessary to draw up an accurate drawing of the luggage rack for the car planned for production, with the dimensions of the parts marked on the diagram. In this case, the drawing must necessarily contain the following structural elements:

• General dimensions of the product;
• Length and location points of transverse reinforcing bridges;
• The height of the sides of the future design;
• Trunk bottom.

When developing a project, it should be borne in mind that roof racks, which have a rectangular or square shape, create significant air resistance during the movement of the car. Because of this, the aerodynamic performance of the car can be seriously affected. To prevent this from happening, it is recommended to make a trunk with a streamlined headboard.

Manufacturing

The process of making a roof rack for a car with your own hands has the following sequence of actions:

1. Carefully study the created design drawing.
2. Trim the metal to create the trunk frame. The work is done using a grinder.
3. From a suitable metal with a grinder, cut the elements that will later become the stiffeners of the product. If there is no need to transport very heavy loads, it is enough to prepare two longitudinal and transverse elements.
4. Weld pieces of metal together so that you get two identical rectangles. One of them will be the bottom of the trunk, and the second is needed as a side.
5. Strengthen the lower rectangle by welding stiffeners to it, at the same distance from each other.
6. Spliced ​​together the bottom of the structure and the side. This can be done by welding at the corners of rectangles, placed one above the other, and at several points on the sides, metal rods or tubes of a diameter smaller than the main structure.

At the end of welding, the metal is lightly sanded and painted in the color selected for the structure.

Car roof mount

To install a car rack on the roof of a car with your own hands, you will need rails mounted on the sides. If they are not there, these elements can also be made by yourself. This requires:

1. Using a grinder, cut out two pieces of the same size from a metal pipe, suitable for the length of the roof.
2. A generous layer of polyurethane foam is applied to the metal on all sides and left to dry completely.
3. After the foam has hardened, with the help of grinding tools, the products are given the required shape.
4. The resulting crossbars are covered with glass cloth in 2-3 layers.
5. The finished roof rails are painted black or any other suitable color.

After that, the roof rails are mounted on the roof of the car using clamps for car mufflers. All unnecessary parts of the clamp are cut off without fail so that in the end only a flat plate is obtained on the railing. Further, symmetrical mounting holes are drilled in the rails on both sides. The prepared plates must be drilled at the same points. After these manipulations, the cross members are bolted to the roof of the machine. If the products do not fit snugly, a small rubber gasket can be placed between the plate and the railing.

The finished rack is attached to the roof rails using brackets. In the absence of crossbars and unwillingness to do them yourself, the trunk can be attached to the roof of the car directly. However, in this case, you will have to drill holes for the brackets in the car body, and fix the roof rack with their help.

For long-term and successful operation of a self-made trunk, the product must be periodically cleaned of road debris, sanded and repainted. Having chosen metal pipes as a material, the decorative and protective coating should protect the product from corrosive processes.

Also, in order for the trunk to serve for a long time, it is important not to overload it, but when filling it, make a careful distribution of the weight of the baggage over the entire area of ​​the structure.

Yes, you will be glad. We are glad until you see the price tag. Another thing is an expeditionary trunk with your own hands. It is necessary, however, to think over a few questions about the shape and weight of the cargo that you are going to transport.

Materials and market trends

We present to you the main contender for the standing ovation - aluminum. Aluminum sheets are lightweight and difficult to bend or puncture.

More often, the owners of domestic cars want to do this kind of work with their own hands. Take, for example, a Niva or UAZ roof rack. A suitable material for the construction will be a profile thin-walled pipe. In other cases, ferrous metal or stainless steel are possible, as well as many others.

Step-by-step manufacturing instructions

As an example, let's take a luggage rack made from a metal profile.

We measure the length and width of the roof. We need to find out the weight of the future structure, taking into account the material and the measured parameters. How to do it? Microsoft Excel to help you. The weight of the structure will be shown immediately after all characteristics have been recorded.

We will weld the perimeter of the future trunk, and at an equal distance inside the perimeter we weld two jumpers that will "hold" the structure. Roof rails will be installed to these jumpers, and we will already connect the platform to the rails. After the main intermediate jumpers, for greater strength. This completes the collection of the supporting frame.

Further, the profile pipe comes into play. It will serve as a connecting element between all the jumpers. For the aesthetics and aerodynamics of the luggage compartment, a roll bar is installed at the front of the structure. There should be a sector in the places of its bend, and at the edge - a 5 cm overlap. Weld the arc with the front part of the surface, and also add jumpers.

What is an expeditionary trunk without boards? It is advisable to make removable sides in order to change them as needed. The sides will be attached to the holes that need to be scalded and plugged with bushings. This will eliminate the deformation of the profile when tightening the bolts.

Now how to make the boards themselves. We need 8 racks, each about 6.5 cm long. The fastening pin can be welded only when between two holes, which we will do. After drilling two holes, weld the stud.

Side top bar

Have you forgotten how we flexed the front arch? We also bend the side top bar. One, the other. Next, we weld the sleeve to the bending point of the crossbar from the side, so that the upper part of the front crossbar is securely fixed.

That's almost all the work is done. The hour has come for creative motorists. You need to paint the whole structure, give it a little style. To avoid rusting, we advise you to apply a layer of primer, and only then think about the paint. Among soil solutions, the most resistant to salt influences is soil, which contains zinc.

After applying a layer of primer, you should wait at least a day, and then use ordinary enamel and apply the desired color. Many people do not like the way the bolts look at the joints of the structure. To avoid an ugly look, you can put decorative nuts in these places. So much for a modern trunk.

What else to add?

The main function of the roof rack is to save space inside. With the installation of additional equipment, you can expand its functionality.

1. "" - lanterns that will illuminate the road even better.
2. The inner and outer sides have room for a hijack and a shovel. Oh, how happy the gardeners will be.
3. If you often drive through overgrown areas, such as forests, you can install branch baffles. They will protect the glass from damage.

Do not forget also that the expeditionary protects the roof itself well from dents. As you can see, such a rack can be a good tool not only to save space, but also to install useful equipment. In addition, in addition to the luggage racks themselves, other structures can be attached to the rails for transporting fishing or hunting equipment.

As you can see, making a trunk with your own hands is real. Large Mitsubishi L200s require a side ladder. For small foreign cars, a reinforced frame will be enough.

Almost every driver faced such a problem as a lack of space in the trunk of a car. And this applies not only to connoisseurs of outdoor activities, who regularly go out into the countryside and bring bicycles, tents and household items with them. In everyday life, the problem of transporting bulky items from place to place often appears.

An additional cargo area on the roof would be a good option for solving such problems. If the manufacturer does not expect this element in the standard equipment of the car, a do-it-yourself car roof rack will be a good alternative. It is a removable structure that can be easily mounted on a car and just as easily removed.

The most common types of homemade roof racks are a car box and a welded structure made up of aluminum or steel profiles.

The box on the roof of the car has a rather attractive appearance and, most importantly, does not violate the aerodynamic performance of the car. But making it yourself is quite difficult and costly. It is included in the factory configuration, which is developed for a specific car brand, most often for SUVs.

The rack and pinion roof rack is a more functional design. The volume of the rack and pinion compartment on the roof of any VAZ model is two to three times the volume of an autobox on a Toyota SUV.

The advantages are obvious:

• the structure can be installed temporarily;
• ease of transporting bulky items: pipes, bicycles, boards, etc.;
• car roof protection;
• increase in the volume of the cargo compartment two to three times.

Disadvantages:

• decrease in vehicle aerodynamics;
• if the weight of the cargo on the roof is from 50 kg, the stability of the car decreases by 10-20% in case of side gusts of wind;
• car driving becomes more difficult.

The main disadvantage is that fuel consumption increases to 1-2 liters per 100 km with a load of 50 kg.

The average speed of a car with a load of 50 kg on the roof should not exceed 70-75 km / h.

How to make a trunk

If the car is equipped with roof rails - standard metal railings on the roof - it is recommended to make aluminum or steel crossbars that will serve as the bottom of the trunk.

If roof rails are not provided in the standard equipment of the car, you can make a welded structure of the trunk with the bottom and sides. Doing it yourself is impractical, the cost of work and materials will cost 50-60% higher than buying a ready-made trunk.

The trunk manufacturing process is conventionally divided into the following stages:

1. Material selection, tool preparation.
2. Taking measurements, drawing a drawing.
3. Making the perimeter and fasteners of the trunk with your own hands.
4. Welding.
5. Installation of the trunk on the car.

Materials and tools

One of the main stages of production during self-production is the correct calculation of the weight of the finished structure and the creation of a drawing. The ideal material for a car trunk will be aluminum profiles. Aluminum is highly durable, flexible and lightweight.

Shaped pipes can become an alternative material. The weight of the material is relatively small, the thin-walled profile pipes are resistant to corrosion, high strength and low cost. The cost of a profile pipe is half that of a similar aluminum pipe.

Strips of stainless steel sheet should be used as a roof rack material in extreme cases as the material is heavy and expensive.

For the manufacture of fasteners, you can use prepared industrial steel plates.

Of the tools you will need:

• Bulgarian;
• welding machine;
• Sander;
• primer;
• car paint.

Measurements of the structure and drawing up a drawing

If you need to make your own roof rack, where standard roof rails are installed, you just need to measure the distance between them. Fasteners. If these elements are absent in the car, then it is required to measure the length and width of the roof. Based on these numbers, a design drawing is created, where the following parameters are calculated:

• length and width of the frame;
• a place for reinforcing jumpers is determined;
• the height of the sides is calculated;
• the number of fasteners is determined.

While drawing the drawing, streamline the front board, and install an aluminum arch in the front of the structure. If the roof length is more than 2.5 meters, six support points are required, if less, four fasteners are sufficient.

According to the drawing, blanks are cut from the selected material, then the frame is welded.

Welding works

The correct manufacture of the trunk with your own hands depends on the accuracy of the preliminary measurements and the design drawing. Welding works are carried out in the following sequence:

1. The perimeter of the structure is welded from a profile pipe or sheet of steel, depending on the selected material.
2. Jumpers are welded to strengthen the bottom. Considering the weight of the cargo that is supposed to be carried on the roof, you can weld on the lintels with a grid.
3. An aluminum bow is welded to the front of the platform to ensure optimal aerodynamics of the vehicle.
4. For the sides, racks with a length of 6-15 cm are cut. The side racks are welded to the upper part of the frame, which coincides with the base, the bottom.
5. The sander removes the beads of material that remain after welding. The crossbeam mountings are ground and primed.
6. Painting of the structure. A primer is made before painting.
7. Installation of roof racks or roof racks. To install the roof rack, brackets are mounted directly on the roof, on which the cargo compartment will be installed.

Tool steel is heavy, do not use more than three strips of steel to reinforce the bottom of the boot.

Providing aerodynamics and fixing the sides

In order to minimize the decrease in the aerodynamic performance of the car due to the installation of a self-made roof rack, it is recommended to use an inclined mount of the struts on the front and rear of the structure.

To do this, the upper side tubes should be slightly smaller than similar lower ones. Therefore, the racks on the front and rear of the bottom of the structure are welded at an angle. The angle of inclination and the length of the upper side parts are calculated in the process of drawing up the design drawing.

Aesthetic touches

After all welding work, the machine structure is carefully ground, primed and painted. Degrease the parts before priming.

Using a primer with a high zinc content will protect the metal roof rack as much as possible from corrosion and facilitate painting.

A few days after the structure is primed, painting is done.

As an additional aesthetic touch, decorative nuts can be installed that completely cover the mounting bolts.

Additional devices and devices

On the expedition roof rack, you can install automotive equipment that will provide the driver with additional comfort:

• installation of fog lamps is allowed;
• you can make and install a windbreak: if a trip to the forest is planned, this will help protect the windshield;
• the second antenna on the trunk can come in handy when traveling to distant places.

According to the traffic police rules, the installation of a trunk is not a re-equipment of the car and does not require registration, if, according to the design of a particular car model, for an additional luggage compartment.

Motorists are often worried about the lack of free space in the car, which is necessary for transporting things, equipment, machinery, building materials or other items. Many cars are simply not designed to carry any additional items and cargo. If you often go to activities such as fishing, hunting with friends, or traveling with your family at sea, then you need to think about additional space on your car for transporting cargo. Unfortunately, in most cars when buying, the kit does not provide an additional roof rack.

Homemade trunk

A good option would be to make a homemade roof rack designed for the roof of your car. This option is very economical, and with a small amount of effort, you can acquire invaluable skill in designing, calculating and manufacturing a structure on your own. Such homemade luggage racks are called expeditionary ones, since you cannot put too heavy things on such a structure, but you can carry everything you need for the trip on them: tents, bicycles, skis, mattresses, umbrellas, snowboards, fishing rods, or whole sets of clothes.

Roof box

Also, a very popular type of homemade trunk is an auto box. The advantages of this design are that the transported things will be safe even in bad weather, and the design of the auto box itself, made with a streamlined shape, will not affect the aerodynamic properties and fuel consumption of your car. Now, when buying a car, it is very rare to provide a trunk in the kit, despite the presence of a specially equipped place and fasteners for its installation. Therefore, you can make a trunk with your own hands based on the necessary parameters of your car.

Homemade roof box

Do-it-yourself roof rack

In order to make with your own efforts a roof rack designed for the roof of your car, you need to do the following:

1. We select the material for the manufacture of the trunk:

First you need to choose the material from which you will make this structure. The best material will be metal, as it is durable and reliable. But for such a trunk you need a material with a low weight, and reliable, durable characteristics. The most suitable option would be an aluminum alloy, because this metal is easily processed and formed into the desired shape, does not corrode, and has a low specific gravity. Also, some use a thin-walled profile pipe for the manufacture of trunks. One of the most economical roof rack materials is stainless steel sheet. Many people use it for the manufacture of such structures. But the disadvantage of this material is its high weight and high cost.

Square tube for making trunk

1. We measure the car:

After you have chosen the material from which you will make the trunk, it is important to make accurate measurements of the car. Thanks to this, you can calculate the required amount of material, its weight, and the approximate price.

Trunk measurements

In order to make it easier and more convenient to manufacture, you can pre-measure the dimensions of the car (width and length), and draw up a drawing:

• sides;
• frame;
• bearing part (panel) - the bottom of the trunk, which serves as its reinforcement;
• jumpers - elements that reinforce the trunk.

The front side can be streamlined, which will significantly improve aerodynamic properties.

Now that you have decided on the material, you must follow the detailed instructions below:

1. We cut out the profile according to a previously prepared scheme, using a grinder for this;
2. Using welding, we make the perimeter of the trunk. This part will be rectangular;
3. The resulting perimeter should be reinforced by welding straight jumpers onto it. For a stronger reinforcement, you can weld jumpers together, resulting in a lattice base of the trunk;
4. A metal profile arc should be welded to the front of the trunk to create a more streamlined shape and improve aerodynamic properties;
5. Next, you need to make the sides of the structure. First, we cut the metal racks 6 centimeters long. In most cases, craftsmen make the sides removable, so the sides need not be welded easily into the frame, but screwed into the thread. What is needed for this? It is necessary to drill holes in the frame into which the bushings are welded. These elements are necessary to prevent deformation of the bolts when screwing in;
6. Next, you need to weld the racks to the upper crossbar, which completely coincides with the base, differing only in that its side parts - right and left - are made a little shorter. The racks, which are located in front, are installed at a slight angle so that the resulting structure does not look like a box or box, but completely repeats the main contour of the car;
7. After the completion of welding, the next stage is painting and installation on the roof of the car. Before painting the body, you need to apply a layer of primer, and let the primer dry for some time, this is necessary so that the paint stably holds for a long time and does not flake off. Next, you can apply a layer of paint, and the best option is if it is paint in cans, since there will be no drips from it;
8. Fastening the trunk to the car. If roof rails are provided on the car roof, then the roof rack is installed on them. These body elements are able to withstand the load of the trunk. If there are no rails, then you will have to drill holes in the roof and install the brackets, on which the finished structure is then mounted. Some vehicles have grooves for mounting a roof rack. Also, if you do not want to drill your roof to install the brackets, you can find various mounts specially designed for such cases.

Homemade trunk for a car

Advantages and disadvantages of similar homemade trunks

Each type of roof rack has its own advantages and disadvantages. The advantages of such products include:

• increase in space for cargo transportation;
• protection of the roof of a car from impacts or dents;
• the ability to transport boats, skis, bicycles, boxes, suitcases, snowboards, fishing rods, and construction equipment.

The disadvantages of such trunks include:

• deterioration in car handling due to improper distribution of cargo;
• deterioration of the aerodynamic properties of the car;
• the noise level in the cabin increases;
• increased fuel consumption due to drag forces.

Moscow Automobile and Highway State University, Moscow. Education level: Higher. Faculty: AT. Specialty: Engineer spec. Automobiles and automotive industry. Experience in the automotive industry (master consultant ...

14 comments

Sergey says:

It has long been a desire for an extra roof rack. Since it is simply irreplaceable for transporting bicycles, scooters and boats. But I did not want to spend money on this benefit at all. By the way, the collection scheme is practically the same for all cars, so the choice is not great. The money spent is several times less than the cost of buying and installing a new one.

Valery says:

And I'm worried about the question, how much can he withstand? Does the roof not bend?

Valentine says:

We use such a trunk at work. Be calm, a quarter of a ton can stand calmly, and in ordinary life you will not need to transport any more. By the way, they also did it at work, with colleagues, the time did not take as long as I would have done it alone.

Alexander says:

First came the idea to buy. But after looking at the prices, I decided to do everything myself. The mechanism for making such a trunk is understandable and accessible to almost everyone. If you have a good welding machine at home, everything will work out. At first glance, there are no difficulties. The only thing is that there may be slight hiccups in attaching the trunk to the car. So you may have to resort to the help of masters.

Top rack - what is it? Is it a functional element of a modern car or an unnecessary part that does more harm than good? You can argue about this endlessly, because the needs and methods of operating the car are different for each driver. Someone uses a vehicle only to get to work in the morning and home in the evening. Others cannot imagine their life without active sports: cycling, skiing and snowboarding. The last category of people, perhaps most of all, needs to install additional space for attaching large-sized items. By the way, it is quite possible to make an expeditionary trunk in the garage with your own hands.

Do you need a roof rack

Not all modern cars have an additional expeditionary rack, however, this is a very important and useful part of the car. Usually they remember about it when it is required to transport a large-sized object. Owners of cars with a "coupe" or "sedan" body type will be forced to hire carriers if they need to buy building materials for a summer cottage or garage, because boards and pipes simply will not fit in the trunk. Even an ordinary bicycle can be stowed in the regular luggage compartment of not every car. Someone might argue that there is a trailer for these purposes. But driving such a vehicle requires certain driving skills, and not everyone has a trailer. A way out of such situations will be the purchase or independent production of a roof rack for a car.

These racks can be divided into two categories:

• boxes;
• arcs-crossbars.

The former are more compact and have an attractive appearance. Plus, they protect your belongings from dust, rain, snow and even bright sun. However, they are able to accommodate much less things than arcs-crossbars, and it is almost impossible to make them yourself.

But the second option is more functional, moreover, it is not difficult to do it yourself.

Modern manufacturers are increasingly producing combined types of roof racks. For example, a box and a holder for bicycles and other sports equipment can be combined in one design. If you wish, you can purchase such devices in specialized stores, but making them with your own hands is almost impossible.

Pros and cons of expeditionary trunks

If you're still not sure if you need a roof rack in a location like this, check out the pros and cons of this part. The positives of the Expedition Rack are pretty obvious:

• it allows you to carry more things;
• protects the roof and its paintwork from external damage from above;
• it becomes possible to transport bulky items;
• with reliable fixation, the load will not fall;
• transported items do not obstruct the driver's view;
• free space in the car;
• for some body structures, it becomes possible to increase the volume of the cabin due to the empty luggage compartment;
• you can install LPG equipment in the vacated regular trunk;
• such a detail is easy to do with your own hands

Unfortunately, such a trunk also has negative qualities:

• the weight of the transported items is limited by the carrying capacity of the vehicle;
• fuel consumption increases by 2 liters for every thousand kilometers with an empty trunk installed;
• you will have to apply certain physical efforts, lifting the load to the height of the machine;
• with excessive filling of the trunk or poor fixation, you can lose some of the things;
• improperly fixed structures rattle and interfere with the driver;
• the aerodynamics of the car is reduced, due to which the possibilities for acceleration and maneuvers are reduced;
• the machine becomes less resistant to crosswind;
• the vehicle's height increases, which means that you need to be careful when driving through tunnels or under low arches.

The need to install an expeditionary luggage rack directly depends on the features of vehicle operation. If you travel often, like to ride bicycles with your family and friends, or do summer cottage work, then such an element of the car will be indispensable for you. In all other cases, it will not be superfluous to have a similar trunk, besides, it can always be dismantled and left in the garage, and, if necessary, installed back.

How to make a trunk with your own hands

Expedition rack can be made in two ways:

• weld a metal structure with sides and bottom;
• make crossbars for roof rails.

Roof rails are a kind of railings installed on the roof of a car. Simple weights can be tied directly to them, but this can damage the paintwork. Unfortunately, roof rails are not available on some car models, so sometimes it may be necessary to manufacture a complete structure.

If you plan to dwell on the method of attaching crossbars to rails, then the whole process can be conditionally divided into several stages:

• selection and purchase of the necessary materials and tools;
• measurement of the parameters of the car roof;
• drawing up a design drawing;
• production of crossbars;
• manufacture of fasteners;
• assembly of the structure;
• installation of the trunk in its place.

In the event that the roof rails are not provided for in the design of the car, it may be necessary to weld a more complex shape of the trunk. However, with a responsible approach to the situation, from the beginning of measurements to the installation of a finished structure on a car, it can take no more than one day.

Choice of material and tools

The choice of material for the manufacture of expeditionary luggage should be taken with full responsibility. Heavy materials will significantly increase the vehicle's weight, which will affect agility and acceleration. In addition, such materials are quite difficult to work with. Give preference to light and soft metals and structures. The best solution would be to choose aluminum, since it is lightweight, but strong enough. It is a flexible and soft metal, so it shouldn't be too difficult to work with. Moreover, aluminum is not afraid of corrosion.

Of course, the price for this metal is slightly higher than for many others. If aluminum is too expensive for you, pay attention to the profile thin-walled tube. It can also serve as a good material for a future product. But sheet stainless steel should be used only as a last resort, since it is quite heavy.

In addition to the metal itself, you will need other materials and tools. These include:

• welding machine
• grinder for metal cutting;
• clamps for car mufflers;
• polyurethane foam;
• grinding equipment;
• fiberglass with a density of at least 300 g / m2;
• car paint (if desired).

As for the paint, you can choose it in the color of the car body, or you can stay at the classic black or silver color.

Measurements of the structure and drawing up a drawing

In order to make cross members, you just need to measure the distance between the rails. But for the manufacture of a more complex structure, it is necessary to determine the size and weight of the future trunk, and at the same time draw up a project. The amount of materials that you need depends on this. To prepare a drawing of a future product, you need to accurately measure the length and width of the roof..

After that, create a drawing, which will take into account the following elements of the trunk:

• parameters of the structure frame;
• the length and location of the bridges reinforcing the product;
• the bottom of the trunk;
• the height of the sides of the structure.

When designing a structure, pay attention to the following point: rectangular roof racks have a negative effect on the aerodynamics of the car. Therefore, it is recommended to make the headboard more streamlined.

Method One: Making Crossbars and Fasteners

First of all, we will deal with the manufacture of crossbars. Decide on their length in accordance with the drawing, and then get to work.

1. Using a grinder, cut two crossbars of the required length. Make sure they are the same size.
2. Apply polyurethane foam generously to the inside and outside of the metal.
3. Wait for the foam to harden.
4. Now, using a grinder, grind off all unnecessary and give the crossbars the desired shape.
5. Cover the resulting products with fiberglass in two or three layers.
6. Paint the item in your chosen color.

Photo instructions for the manufacture of crossbars

After that, you need to start making fasteners. For them, clamps for car mufflers are used. In this case, all unnecessary elements of the clamp are cut off to leave only a flat plate. With its help, the crossbars can be securely attached to the rails.

To assemble such a structure, symmetrical holes are drilled in the rails on both sides. The distance between the holes must be the same as on the prepared mounting plates. After that, the cross members can be easily installed in their places.

If the crossmembers do not fit snugly against the mountings, you can seal these areas with rubber washers.

Video: making crossbars and attaching them to rails

Method Two: Making a More Complex Expeditionary Trunk

The second method is more suitable for making roof racks for off-road vehicles. It has a slightly different procedure, thanks to which you can create a more complex structure with a bottom, stiffening ribs and sides.

This method is best used if you are transporting really bulky items or if your car does not have roof rails to which you can attach crossbars.

1. Carefully study the previously prepared drawing. Decide on the length of all structural elements.
2. Using a grinder, cut the metal to make the frame of the structure. You should have two longitudinal and two transverse metal pieces for the bottom and top of the structure.
3. Weld the metal pipes together in such a way that you get two rectangles corresponding to the parameters of the roof.
4. The lower rectangle should be reinforced with stiffening ribs, placing them across the structure at the same distance from each other. If desired, you can add a construction mesh to the bottom frame.
5. Now it is necessary to connect the upper and lower rectangle, thus forming the sides of the trunk. To do this, you need metal pipes with a smaller diameter.
6. Prepare an even number of metal pieces ranging from 7 to 15 cm in length, depending on the estimated depth of the trunk.
7. Place them symmetrically on all sides of the rectangle, and then weld the top and bottom of the trunk.

Photo instructions for the manufacture of expeditionary luggage rack with bottom and sides

Weld four crossbars in the shape of a rectangle (you will need 2 of these blanks) Connect the upper and lower rectangles Add stiffeners to the structure Apply anti-corrosion primer to the metal

Please note that to improve the aerodynamic properties, it is better to make the front and rear sides not from a straight line, but from an arcuate segment.

If you have worked with a material that is not resistant to rust, be sure to treat it with a special anti-corrosion compound. If you wish, you can also foam the resulting structure, reinforce it with fiberglass, and then paint it in the desired color.

Video: making an expeditionary luggage rack with a frame and sides

If you do not have roof rails, to install such a rack you will need to drill the roof and fix it with special brackets. Unfortunately, this can cause rust in the holes when moisture gets on the metal, so it is better to contact a special auto repair shop to solve the problem.

Expedition Rack Accessories

Interestingly, some additional devices can be installed on the roof rack to make life easier for the driver. So, for example, if you often visit the country and carry special equipment with you, the structure can be equipped with a special mount for a shovel. This same mount can be used on fishing trips to secure fishing rods.

Also, you can easily install a mount for the radio antenna on the trunk, which will significantly improve signal reception. If you often ride outside the city, in places with a large congestion of trees, then you need such a thing as windbreaks. On one of the sides, they can be fixed on the frame of the expeditionary rack, and thereby protect the windshield from damage.

But the most popular additional equipment for this element of the car is lighting elements, the so-called chandeliers. They are a series of headlights that illuminate more space in front of the vehicle than conventional near and far lamps. Many people install fog lights on the trunk, but the principle of supply and diffusion of light in them is not very suitable for lighting from above. Today on sale you can easily find special lamps for overhead light sources.

As you can see, making a trunk yourself is far from the most difficult procedure. Of course, when making a complete structure with a bottom and sides, you need to have certain skills in welding metal structures, as well as special equipment. Therefore, in some cases it may be advisable to consider purchasing and installing a ready-made part.