A roof rack is needed, as a rule, for those who often carry oversized items in a car. This may be due to work or home repairs, but, in fact, many drivers do not need to drive every day with a roof rack. If you have a long trip or need to transport something, then roof racks are easy to mount. The situation is the same with the purchase of a roof rack - for a foreign car it is not cheap, few people need it for daily use, but it would not be bad to have it in stock. There is a way out of this situation, requiring a minimum investment of funds - a do-it-yourself car roof rack.
Of course, if your car is equipped with roof rails, like most of today's foreign cars, then you can buy ready-made roof boxes. They are a closed trunk, in which you can put a fairly large number of things that do not fit in a regular trunk. But if you need to carry, for example, a long ladder, pipes or something like that, then you will have to use open roof mounts. Today we will figure out how to make them yourself so as not to spend extra money.
Choosing a material
Before we start manufacturing the trunk, we need to decide what materials we will use. We will need the following things:
- Metallic profile. From it will be made transverse trunk brackets. A profile with a section of 20x30 mm is optimally suited, do not take it too thin, the walls are preferably at least 2 mm each. You also need to recall that the trunk must have a smooth, even surface, so you can’t use pipes - the load will slide off them.
- Clamps for mounting the muffler, it is easy to make fastening the profile to the roof from them.
- Mounting foam.
- Sander.
- Paint in the color of the car.
To choose the right paint, refer to the manufacturer's color palette, you can find the color marking there.
Manufacturing of cross members
So, we will carry out the trunk according to the type of those that are now sold, with two crossbars through the roof. To homemade version had a soft and attractive appearance, at the final stage we will cover the profile with mounting foam and fiberglass, give it the desired appearance.
The step-by-step instruction looks like this:
Now it remains to make a mount to put our new trunk to the car.
Manufacturing of fasteners
The simplest way make the mounts yourself - remake the clamps for mounting the muffler from almost any car. They look like a flat bracket on one side and an arc around the pipe on the other. We need to saw off the excess so that a flat plate remains. It will fit snugly against the crossbars and rails, providing a secure fit. So that the clamps do not stand out, it is advisable to paint them in the same color as the trunk - the view will be more pleasant.
If there is no desire to be tricky with clamps, then you can use threaded U-shaped brackets for this. And instead of ordinary nuts, put on lambs that can be quickly unscrewed and tightened. This solution significantly speeds up the installation process of the trunk.
Crossbar fastening
To fix the already prepared crossbars to the rails, you need to make special holes in them. Measure them symmetrically on both sides, taking into account the holes in the mounting plates that we prepared earlier. After you drill the hole, you can begin to mount the trunk. Having fulfilled all the conditions, it will take you no more than 15 minutes to secure. If you notice that the fasteners are loose somewhere, then you can use rubber gaskets, even homemade ones.
After placing the trunk, make sure that it fits snugly against the rails. Do not forget about safety precautions - you can not load the roof by more than 70 kg. Roof boxes can withstand more, but it's not worth breaking and taking risks.
If you load more, then you risk not only harming not only the trunk, but also the roof itself. In addition, if it is a heavy oversized cargo, then you need to consider that you need to secure it correctly.
As you can see, there is nothing complicated in making a roof rack on your own, the process does not require any special knowledge and you can do everything yourself. Everything can be done right in the garage of any car enthusiast, the tool required is minimal. The main thing is not to forget about safety during work.
Top rack - what is it? functional element modern car or an unnecessary detail, from which there is more harm than good? You can argue about this endlessly, because each driver has his own needs and methods of operating the car. Someone uses a vehicle only to get to work in the morning and home in the evening. And 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 items. By the way, forwarding trunk It is quite possible to make in the garage with your own hands.
Do you need a roof rack
Not at all modern machines an additional forwarding trunk is installed, however, this is a very important and useful part of the car. Usually it is remembered 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 house or garage, because boards and pipes simply won’t fit in the trunk. Even an ordinary bike can be put into a standard one. luggage compartment not every car. Someone may object that there is a trailer for these purposes. But such management vehicle requires certain driving skills, and not everyone has a trailer. The way out of such situations is to purchase or independent production car roof rack.
Such trunks can be divided into two categories:
- boxes;
- arc-crossbars.
The former are more compact and have an attractive appearance. In addition, they protect your belongings from dust, rain, snow and even the bright sun. However, they are able to accommodate much fewer things than arc-crossbars, and it is almost impossible to make them yourself.
But the second option is more functional, besides, it is easy to do it yourself.
Modern manufacturers are increasingly producing combined types of trunks. So, for example, in one design, you can combine a box and a holder for bicycles and other sports equipment. 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 forwarding trunks
If you are still not sure if you need a trunk in such a place, check out the advantages and disadvantages of this part. Positive sides expedition trunk are pretty obvious:
- it allows you to carry more things;
- protects the roof and paintwork from external damage from above;
- it becomes possible to transport large items;
- with reliable fixation, the load will not fall;
- transported items do not block the driver's view;
- free up space in the car;
- for some body designs, it becomes possible to increase the volume of the cabin due to the empty luggage compartment;
- you can install gas 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 things;
- incorrectly 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 side wind;
- the height of the car increases, which means that you should be more careful when driving through tunnels or under low arches.
The need to install an expeditionary trunk directly depends on the characteristics of the operation of the car. If you travel often, like to ride bicycles with your family and friends, or do summer work, then such an element of the car will be indispensable for you. In all other cases, having such a trunk will also not be superfluous, 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
Expeditionary trunk can be made in two ways:
- weld a metal structure with sides and bottom;
- make cross bars for railings.
Roof rails are a kind of railing installed on the roof of the car. Simple shaped weights can be tied directly to them, but this may damage the paintwork. Unfortunately, roof rails are not available on some car models, so sometimes it may be necessary to manufacture complete construction.
If you plan to dwell on the method of attaching the crossbars to the rails, then the whole process can be divided into several stages:
- selection and purchase necessary materials and tools;
- measurement of car roof parameters;
- drawing up a design drawing;
- manufacture of crossbars;
- manufacture of fasteners;
- construction assembly;
- installing the trunk in its place.
In the event that 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, it can take no more than one day from the start of measurements to the installation of the finished structure on the car.
Choice of material and tools
The choice of material for the manufacture of the forwarding trunk should be taken with all responsibility. Heavy materials will significantly increase the weight of the car, which will affect maneuverability and acceleration. In addition, it is quite difficult to work with such materials. Give preference to light and soft metals and structures. The best solution would be to choose aluminum, as it is light in weight, but at the same time quite durable. It is a flexible and soft metal, so working with it will not cause any particular difficulties. In addition, aluminum is not afraid of corrosion.
Of course, the price of this metal is somewhat higher than 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, as it has a rather large weight.
In addition to the metal itself, you will need other materials and tools. These include:
- welding machine
- grinder for cutting metal;
- clamps for automobile mufflers;
- mounting foam;
- grinding equipment;
- fiberglass with a density of at least 300 g / sq.m;
- car paint (if desired).
As for the paint, you can choose it in the color of the car body, or you can stop at the classic black or silver color.
Structural measurements and drawing up
In order to make crossbars, you only need to measure the distance between the rails. But for the manufacture of a more complex design, it is necessary to determine the size and weight of the future trunk, and at the same time draw up a project. It depends on the amount of materials that you need. 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 that will take into account the following elements of the trunk:
- structure frame parameters;
- the length and location of the jumpers reinforcing the product;
- trunk bottom;
- the height of the sides of the structure.
When designing a structure, pay attention to the following point: rectangular trunks adversely affect the aerodynamics of the car. Therefore, it is recommended to make the front side more streamlined.
Method One: Making Crossbars and Fasteners
First of all, let's make the crossbars. Decide on their length in accordance with the drawing, and then get to work.
- Using a grinder, cut two crossbars of the required length. Make sure they are the same size.
- Liberally apply mounting foam to the metal inside and out.
- Wait for the foam to harden.
- Now, using a grinder, grind off all unnecessary and give the crossbars the desired shape.
- In two or three layers, cover the resulting products with fiberglass.
- Paint the product in the chosen color.
Photo instructions for making crossbars
After that, you need to start making fasteners. For them clamps for automobile 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 this design, symmetrical holes are drilled in the rails on both sides. The distance between the holes should be the same as on the prepared fixing plates. After that, the crossbars are easily installed in their places.
If the crossbars are not tight enough to the mounts, you can seal these places with rubber grommets.
Video: making crossbars and attaching them to the rails
Method two: making a more complex expeditionary trunk
The second method is more suitable for the manufacture of trunks designed for SUVs. It has a slightly different procedure, thanks to which you can create a more complex structure with a bottom, stiffeners and sides.
This method is best to resort to if you are transporting really voluminous things or if your car does not have roof rails to which you can attach cross bars.
- Carefully study the pre-prepared drawing. Decide on the length of all structural elements.
- Using a grinder, cut the metal to make the frame of the structure. You should get two longitudinal and two transverse metal segments for the lower and upper parts of the structure.
- Weld the metal tubes together so that you get two rectangles corresponding to the parameters of the roof.
- The lower rectangle should be reinforced with stiffeners, placing them across the structure at the same distance from each other. If desired, a building grid can be added to the lower frame.
- Now you should connect the upper and lower rectangle, thus forming the sides of the trunk. To do this, you will need metal pipes with a smaller diameter.
- Prepare an even number of metal pieces from 7 to 15 cm long, depending on the expected depth of the trunk.
- Arrange them symmetrically on all sides of the rectangle, and then weld the top and bottom of the trunk.
Photo instructions for making an expeditionary trunk with a 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 an anti-corrosion primer to the metal
Please note that in order to improve the aerodynamic properties, the front and rear boards are best made 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 desired, you can also foam the resulting structure, strengthen it with fiberglass, and then paint it in the desired color.
Video: making an expeditionary trunk with a frame and sides
If you do not have roof rails, to install such a roof rack, you will need to drill the roof and mount it using special brackets. Unfortunately, this can cause rust in the holes if moisture gets on the metal, so it's best to contact a special auto repair shop to resolve the problem.
Additional devices for the forwarding trunk
Interestingly, some devices can be additionally installed on the upper trunk to make life easier for the driver. So, for example, if you often visit the country house and carry special equipment with you, the structure can be equipped with a special mount for a shovel. The same mount can be used on fishing trips to fix fishing rods.
You can also easily install a radio antenna mount on the trunk, which will significantly improve signal reception. If you often ride outside the city, in places with a large accumulation of trees, then you need such a thing as vetkootboynik. One of the sides can be fixed on the frame of the expedition trunk, and thereby protect the windshield from damage.
But the most popular additional equipment for this element of the car are lighting elements, the so-called chandeliers. They are a series of headlights that illuminate more of the area in front of the vehicle than conventional low and high beams. Many install on the trunk fog lights, however, the principle of supplying and scattering light in them is not very well suited for lighting from above. Today on sale you can easily find special lamps for overhead light sources.
As you can see, self-manufacturing of the trunk 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 the option of buying and installing a ready-made part.
The main way to increase cargo capacity passenger car This is a roof rack. The trunk allows you to place much more luggage than is provided for by the standard design of the passenger car, in addition, the transportation of things that exceed the dimensions of the car interior (pipes, boards, siding and other building materials) becomes available. Auto shops offer a huge range of luggage designs for both a specific model and universal options. However, all factory trunks are characterized by a considerable cost, which not all motorists can afford to pay. An alternative solution could be to make a roof rack on the roof of the car with your own hands.
Choosing a trunk design
First of all, you should measure the linear dimensions of the roof of the car in order to determine the possible dimensions of the trunk. It must not extend beyond the roof of the vehicle in the area windshield, as well as not create obstacles for opening back door especially if it opens up (or the trunk lid).
To be sure, you can adhere to the dimensions of the factory trunks designed for cars of the corresponding model - such information is available on the manufacturers' websites. In the end, you can arrange with a neighbor in the parking lot or a colleague at work to take measurements and photograph the design of his trunk.
Next, you should decide on the type of luggage you need. For the transportation of goods of various shapes, a trunk in the form of a basket with sides is suitable. If the main type of luggage is long items (roll materials, ladders, etc.), then a flat open platform should be preferred.
You also need to decide on the number of fasteners:
- for sedans and hatchbacks, four points of support will be enough;
- for cars with a roof length of more than 2.5 meters, it is worth increasing the number of mounts to six.
The result of this step should be circuit diagram construction, made in the form of a drawing of the luggage device with an indication of the linear dimensions.
Choosing the material for the trunk
The most common material for making a do-it-yourself roof rack for a car is a metal profile. The best option is an aluminum alloy profile. It is easy to cut and bend to the desired shape, and aluminum is not subject to corrosion and has a low specific gravity.
For a base that has a significant load, you can use a steel rectangular profile with a section of 20x30 mm and a wall thickness of 2 mm. The use of round pipes is less preferable as they can cause the load to slip during transport.
Note! A steel trunk will have a lot of weight, which will ultimately reduce payload transported cargo.
Using a grinder, the profile is cut into elements according to the selected drawing. The rectangular base is welded by electric welding and reinforced with longitudinal struts. To ensure rigidity, the struts are connected by transverse bridges, forming a slatted bottom of the trunk. Further, vertical racks of the required height are made, which are connected to the base with screws. From above, longitudinal and transverse crossbars are welded to the racks, completing the spatial structure of the trunk. Mounts suitable for the corresponding car model are installed at the bottom of the structure.
An example of making a trunk from a metal profile can be seen in the following video:
When choosing metal rolling, preference should be given to stainless steels or consider ways to protect the finished product from corrosion (for example, painting with zinc-containing compounds).
These options are suitable for those who have the ability and skills to use welding equipment. If you cook the trunk according to a unique project from an unfamiliar welder for money, then the total cost of the work may exceed the price of a factory product. Therefore, many motorists use such a not-quite-functional option as lumber to make a trunk.
In principle, the wooden structure successfully copes with the periodic transportation of light loads that cannot be fixed on the standard car rails.
Important! Remember that every 50 kilograms of cargo on the roof increases the height of the car's center of gravity by 10%, which negatively affects the car's handling.
Another option source material It is high impact ABS plastic. Craftsmen with extensive experience in creating fiberglass body kits for cars make roof rails, platforms and even airboxes from polymer compositions, which can successfully compete with branded models in terms of quality and reliability. However, for most motorists, this method of increasing the luggage capacity of a car with their own hands is exotic and almost impossible.
Decide on the type of fasteners
The method of fixing the trunk depends on the design of the roof of the car and on the type of seats for installing the luggage system.
On classic cars such as VAZ 2105-21099 and old foreign cars with longitudinal gutters on the roof to install the trunk, it is necessary to make or select fasteners in the form of a metal stop with a fixing clip on a screw connection. A continuous drain strip allows you to install fasteners at an arbitrary distance from each other, which makes it possible to use luggage systems of various dimensions and carrying capacity.
For machines equipped with longitudinal railings, a different modification of the U-profile clamping fixtures is required. Such mounts for a car roof rack can be made with your own hands from a metal sheet, bent to the shape of the rails and attached to the trunk structure with screws. Often used as a ready-made clamp muffler clamps or construction analogs. The clamp wraps around the railing with a semicircular part, the open ends of the fastening are threaded into pre-drilled holes in the transverse struts of the luggage platform and are attracted by nuts.
To ensure the necessary tightness of the fit of such a mount, it is recommended that sealing gaskets of a suitable shape be cut out of rubber or soft plastic.
Some modern cars have regular places for installing roof rails or trunks. The cargo box is fixed with special transverse screws, which are usually hidden under protective plugs. Unfortunately, for such a design of landing nests, it is very difficult to make fasteners with your own hands. Owners of such cars have to look for used roof rails or broken airboxes of a compatible design that can serve as a donor of mounts for a makeshift roof rack.
Car owners who are going to actively exploit a home-made luggage structure should not forget several important rules :
- for a loaded car, a calm driving style is preferable, without drastic changes speed, turns and lane changes;
- any load must be carefully secured with ropes, tie-down straps or locking devices;
- it is imperative to check the integrity of the structure and the reliability of the fastenings of the trunk before transporting the cargo and after unloading.
The problem of any modern car is the lack of space in the trunk. During daily trips, this is not so noticeable, but when you are going on a long journey or on vacation, the problem of luggage placement becomes a headache for many car owners. Car manufacturers are familiar with this problem, they are fighting for every cubic centimeter of trunk volume, but it is still not enough. In most cases, the problem is solved by installing an additional roof rack on the roof of the car.
Homemade trunk is very convenient to install on rails
Recently, the trunk type "autobox" has become very popular. Its main advantages are a streamlined shape, which affects the aerodynamic performance of the car to a much lesser extent, as well as reliable protection carried baggage from the influence of weather conditions.
Modern cars rarely go on sale with regular roof racks. However, places for their installation are still provided. The cost of transportation devices, even from a little-known manufacturer, is quite high, not to mention famous brands. Therefore, if you have to use the product several times a year, then you can make a roof rack with your own hands, having basic metalworking skills.
Preparatory stage
What to make a trunk
The material for the manufacture of the trunk should be light enough and at the same time durable. Aluminum and its alloys are ideal for this. The material is light, withstands sufficient loads, does not corrode, but has a significant drawback at home, it is quite difficult to work with it. Therefore, most motorists prefer a thin-walled steel profile for this work. And the last option is the use of sheet "stainless steel". Often it is preferred because of its strength and flexibility, while losing sight of the fact that a product made of such a material has a much greater weight than a similar one made of aluminum or steel profiles.
We make measurements
The bottom of the trunk is made in the form of a lattice for greater strength
Before starting work, you should make accurate measurements and draw up a drawing of the product. This will help determine the weight of the structure, approximately calculate the amount of materials needed, and also calculate how much such a trunk will cost you. In the drawing, it is better to immediately indicate all the important elements of the future trunk - its frame, the number and location of jumpers, sides, as well as the supporting bottom of the structure.
To reduce the drag of such a product, you can also make its front part more streamlined. This will help to some extent reduce fuel consumption during the trip.
Getting Started
An approximate workflow is as follows:
- We cut the selected profile with a grinder, according to the measurements made earlier.
- After using the welding machine, we connect the profile around the perimeter in order to get the frame of the future product.
- We strengthen the resulting frame with pre-prepared longitudinal jumpers. To give the structure even greater rigidity, we connect the jumpers by welding several more rows of jumpers across them. As a result, we should get a grille, which will play the role of the bottom of the trunk.
- To reduce air resistance, a special arc of sheet iron and profile is welded to the front. This device will improve the aerodynamics of the product.
- The sides should not be made very high - 10 centimeters is enough. For ease of use, it is better to make them removable, threaded connections here are the best solution. In order to avoid crushing of the supporting frame, a sleeve is usually welded into it, which is used as a pipe of the appropriate diameter.
- The upper crossbar almost completely repeats the shape of the frame and is connected to it with racks.
- The assembled trunk must be protected from environmental influences. Under the influence of moisture, not only the trunk itself is corroded, but drops flowing from it leave hard-to-remove dirty stains on the car. Before painting, the trunk should be treated at the welding points with a grinder, and the rust should be cleaned with an emery cloth or treated with chemical converters. Before painting, the structure should be carefully primed and allowed to dry for 24 hours. When choosing a paint, you should take into account the color and what the car is painted with. For example, on a black car, a salad-colored trunk will look like a misunderstanding. In most cases, the trunk is painted in the same color and type as the car itself. Many motorists for these purposes choose paints in special cans. They do not require sophisticated equipment for high-quality painting, they are resistant to atmospheric precipitation and mechanical damage.
- Such a trunk is attached different ways. For cars equipped with roof rails, there are no problems with mounting the forwarding trunk. In the case when roof rails are not provided, then, most likely, you will have to drill holes in the roof of the car. In fairness, it should be noted that many manufacturers still leave special places for mounting such devices.
Homemade trunk mounts
Advantages and disadvantages
Do-it-yourself installed luggage rack on roof rails can be equipped with additional equipment. In front of the trunk made, you can provide a mount for a garland of fog lights that can be used on country roads. At the rear of the assembled structure, it is possible to provide a platform for mounting a stationary antenna for a radio or TV. To accommodate a shovel and a hijack, mounts can be provided on the outer or inner side walls. With frequent driving on forest roads, it is possible to provide fasteners for wood chippers in the design, which protect the paintwork and glazing of the car from damage.
The roof rack can be equipped with additional equipment, for example, "foglights"
You should know that along with the advantages, forwarding trunks also have a number of disadvantages that reduce the performance of the car and its safety. On a car with installed trunk increased fuel consumption due to increased aerodynamic drag. This is especially noticeable at speeds above 60 km / h. The air currents that form around the trunk create additional noise in the cabin. Unevenly distributed load can lead to poor machine control. But the biggest danger is that the center of gravity of the car shifts, and this can lead to the car tipping over when skidding or making a sharp turn at speed. Therefore, experts recommend making the car roof rack removable and using it only when necessary.
The need to make an expedition trunk with your own hands arises sooner or later for every driver involved in the transportation of bulky goods that are inconvenient for placement in the cabin. As you know, many who have an SUV often go on trips and it happens that a standard trunk does not fit everything you need. This becomes another reason for arranging an additional roof rack.
It is clear to every motorist that buying a finished trunk is a significant blow to the wallet. At the same time, how to make an expedition trunk at home will be a budget and profitable solution.
Suitable materials for the manufacture of expedition luggage
Having decided to make a trunk with your own hands, it is important, first of all, to determine its real weight when designing. Modern models of "expeditioners" are made using especially durable aluminum, which is characterized by low weight and good technical indicators(these are performance qualities, and duration of use, and strength, flexibility, rupture, etc.).
As you can see, aluminum is the best solution when choosing the source material as the basis of the future product. Thin-walled profile pipes can be another option - they also have a low weight. And the third, easiest option is ordinary metal (stripes) or stainless steel. They are somewhat heavy, but easy to handle. It will not be difficult to make and install such a trunk on a UAZ with your own hands. After all, it is the cars of such companies as UAZ and Niva that are most often subjected to independent modifications by their owners.
If you decide to make a trunk for a loaf with your own hands (or for a Niva), then a profile thin-walled pipe may also come in handy for these purposes. For a loaf, ferrous metal or stainless steel is usually an excellent solution. There are plenty of options for choosing a material for constructing a trunk. Much depends on the preferences of the car owner and the functions that the trunk will have to perform.
Main stages of work
With the right approach, you can successfully make a professional trunk - high-quality and visually attractive, like a purchased product. It will differ in that the owner of the car will assemble frame structure, based on their own needs and the functional purpose of the machine. In general, the creation of a roof rack from any material is carried out according to a single scheme, in several stages.
Preparatory design work
Starting to create an external trunk, you should measure the roof and decide on the placement of the supports. Since the dimensions of each car are different, it is necessary to independently measure everything and make accurate calculations, especially when arranging an expedition trunk on the Niva. After that, the design of the future product is thought out: a drawing is drawn and the weight of the trunk as a whole is calculated.
Correctly carry out all the preparatory activities, you can only know such data as:
- made measured parameters;
- possible weight of the frame;
- the most probable weight of all elements of the trunk.
The ending preparatory work should be marked not only by drawing up a detailed drawing, but also by marking on it all the data obtained during the measurement. In this case, you will have to work a lot with your hands and head. After all, only a responsible approach to the implementation of the task will make it possible to manufacture a trunk of such a design and fasteners that will withstand enormous loads.
From words to deeds: we carry out welding work
Having made blanks according to the drawing, they are welded together in the form of a rectangle. At the same time, along the entire inner perimeter of the resulting figure, ponds are fixed opposite opposite points in the middle of the frame. To prevent deflection of the resulting platform during loading, it is recommended to add to the resulting free plane inside the site at equal intervals from 2-3 stiffeners.
Ribs are made of profiled iron. As a result, a kind of frame-lattice is usually obtained with lintels running in a parallel manner. To reinforce the structure itself, a profile pipe with pre-prepared square-shaped cells is used. Thanks to such actions, it will be possible to make a really reliable roof rack with your own hands.
Ensuring aerodynamics and fixing the sides
Thinking through the aesthetics and aerodynamics of the luggage structure, it is worth putting an arc in front. To do this, measure the desired length of the material, with an overlap along the edges of 5 cm. A triangular sector is cut out in the bending zones and bent. Thus, the arc for the front base of the trunk is ready. It remains to attach it to the structure, cut to size and weld. Also jumpers are immediately welded to the arc.
The best option Of course, there will be removable jumpers, because the cases are different. For fastening the sides, holes are made into which bushings of the appropriate diameter are inserted. They are scalded in such a way that the profile does not slip when the bolts are tightened. After that, the sides themselves are made: racks of the required length (usually 6.5 cm) are cut in the required quantity (about 8 pieces).
To arrange the mounting stud, the following steps are performed:
- two holes of 8 cm are drilled;
- a hairpin is placed in them;
- the part is welded;
- the required amount of thread is cut off from it;
- the stud is screwed into the existing holes.
After that, the side upper crossbar is constructed. From the front, the workpiece is bent in the same way as the front frame. The pair element is also done. To fasten the upper front beam, a sleeve is welded to the bend of the side beam, and a piece of stud is welded directly onto the front beam itself. Arrangement of the rear crossbar occurs in a similar way.
If there are doubts about the strength of the manufactured structure, and there is no desire to create a trunk anew, then it is worth welding several amplifiers in addition to the stiffeners. Then the expedition trunk will definitely be able to withstand any additional loads.
aesthetic touches
When making a trunk for a Niva with your own hands, it is important to bring the manufacturing process to the end, namely to paint the finished product. To do this, first clean the platform from scale and burr. Then the metal is degreased and primed to avoid the formation of rust in the future. The best option is to prime the surface with a zinc-containing primer that can withstand exposure to salt solutions.
The drying period of the structure should take at least a day, but it is better that the drying lasts two days. After a long waiting period, it will be possible to start painting the trunk. Enamel is usually used for these purposes. After painting on the trunk, you can put closed decor nuts in the places where the bolts are attached. Do-it-yourself trunk is installed on the car with the help of roof rails.
Devices of additional arrangement
In addition to the fact that the arrangement of the expeditionary trunk is necessary to provide the interior of the car with free space, it also allows you to solve a number of related and important tasks. Use and installation will help to give the roof rack other functions additional equipment with a wide variety of performance options.
Options for additional equipment:
- fog lights are additionally installed on the forwarding trunk, which will make the road more illuminated;
- additional comfort when driving will be given by the radio station antenna installed on the trunk;
- you can attach a hijack and a shovel to the inner / outer sides of the trunk - they can come in handy on the road;
- you can put vetkootboynik on the forwarding trunk, ensuring the safety of the windshield from possible damage when driving through the forest (arrangement of the trunk itself helps protect the roof of the car from a possible tree falling from above).
Thus, the conclusion suggests itself that every motorist who decides to close the issue of lack of space for transporting goods and the safety of the car can make a trunk with his own hands. A carefully thought-out and well-designed trunk will allow you to carry loads of considerable weight and size. With accurate technical calculations, it will not create vibrations or whistling noises during high-speed driving.