We make a car roof rack with our own hands: a cozy nest for your things. How profitable is it to assemble a plywood box on the roof of a car with your own hands? Additional devices and devices

For people who prefer to travel with their family in their own car and have to take a lot of things with them, a roof rack is an essential accessory. It can easily accommodate oversized cargo that does not fit in the rear compartment of the car, and carry sports equipment such as skis, snowboards or bicycles. Usually the trunk is not included in the car, but you can buy it or do it yourself.

Finished box

There are four main types of car trunks:

Classic. Otherwise, they are called universal or basic. They are a structure of metal crossbars and crossbars fixed on the roof of the car. Their main advantage is the ease of fastening and the possibility of modifying the design for the transportation of sports equipment or the installation of a car box.
Expeditionary. This species is designed for fans of outdoor activities, tourists, as well as hunters and fishermen. Such a cargo compartment is more like a basket. In addition to the base, it has sides to which you can attach lighting fixtures, fenders and spares.
Bicycle. The design is a system of fasteners that fix sports equipment.
Autoboxes. They are hard and soft. The hard top cases are made of impact-resistant plastic, while the soft ones are made of fiberglass and look like large travel bags. Fiberglass car box best option for an experienced traveler, because things transported in such a trunk are reliably protected from dirt, wind and precipitation. In addition, the design has a good aerodynamic shape and does not increase fuel consumption too much when fully loaded.

The manufacture of roof racks in the form of boxes is a new, but very promising direction. The cheapest Russian-made models cost from 20,000 rubles, but you can make an autobox on the roof of a car with your own hands.

Do-it-yourself car roof rack

To make a car roof rack with your own hands, you need certain skills and equipment. The work takes place in several stages:

Preparation: determining the design of the car roof rack, measuring and drawing up a drawing of the future product, purchasing materials.
Production: production of parts and fasteners, assembly.
Fixation: fastening of longitudinal and transverse strips, installation of a finished trunk or autobox.

The main factor in choosing the design of the trunk is its purpose. If there is a need to transport not heavy, but bulky cargo, then a universal or forwarding type is suitable. For those who want to free up space in the car from not the most frequently used, but necessary things, ideal solution there will be an autobox.

Attention! However, it is not so easy to make a box on the roof of a car on your own, so classic or expeditionary trunks are more popular among handmade lovers.

Choice of material and tool

When manufacturing the roof rack, it is necessary to take into account the fact that the maximum load on the roof should not exceed 70 kg. The design will be much easier if aluminum profiles are used for its production. They are lightweight, flexible and durable, which, combined with their low weight, makes this material ideal for achieving the goal. An alternative solution may be thin-walled profile pipes. They are also strong and resistant to corrosion, but their cost is almost 2 times lower than that of aluminum.

If, nevertheless, there is a desire to make an autobox, it is better to stop at a soft design, because the manufacture of a case made of fiberglass is technologically difficult and expensive. As a material for soft boxing, a tarpaulin or banner fabric, or fiberglass with a density of at least 300 g/m2 is used.

In addition, you will need the following consumables and tools:

bolts and clamps;
mounting foam;
grinder for metal;
welding machine;
Sander;
primer and car paint.

It is not necessary to match the paint to the color of the car, especially. The design can look aesthetically pleasing and without painting.

cross member

Structural measurements and drawing up

If the design of the machine provides for rails, then for the manufacture of crossbars it is enough to simply measure the distance between them. In their absence, it will be necessary to make accurate measurements of the length and width of the roof, on the basis of which a drawing of the future structure is drawn up. When drawing a 3D model, it is not enough to take into account only the dimensions of the perimeter of the cargo compartment. You will need the following additional parameters:

board or box height;
a place for attaching transverse jumpers and the distance between them;
number of fasteners: if the length of the roof is more than 2.5 m, the structure must have 6 supports. For smaller sizes, four is enough.

As a basis for a pattern for a soft box, you can take drawings that are publicly available on the Internet and adapt them to the desired size. Expeditionary roof rack schemes are quite simple, and you can make them yourself, but it’s easier to build on ready-made solutions.

Welding

Making an expeditionary roof rack with your own hands is impossible without welding. They are held in the following order:

welding of the perimeter of the structure (bottom and side);
welding of transverse jumpers, reinforcing the strength of the bottom of the structure. If necessary, a lattice is made of profiles.
fixing the vertical racks of the sides. They are welded to the bottom and upper frame of the trunk, combining them into a kind of basket;
removal of surfacing from metal resulting from welding, grinding the places of nodes of structural elements with subsequent priming.

Important! In the presence of roof rails, the finished structure is fixed to them using fasteners. If roof rails are not provided, then special brackets are installed on the roof of the car.

Manufacturing of fasteners

There are two ways to make fasteners with your own hands:

From a collar for fastening the muffler of any car. To get the desired result, it is enough to saw off the middle from the flat bar and you will get a universal fastener that will fit snugly against the crossbars and trunk arches.
Use threaded U-bolts. Replace the nuts with "lambs" to make it easier to unscrew and fasten the fasteners.

In order for the fasteners to fit more tightly to the arcs and crossbars of the structure, it is recommended to use rubber seals.

Crossbar fastening

Mounting the crossbars is a very important point. In order to correctly install the autobox on the roof of the car, it is necessary to maintain a distance between them of no more than 50 cm. If the car design provides for rails, then the crossbars are fixed with bolts.

If there are no rails, there are 3 mounting options:

in the standard slots for installing the trunk. Racks are fixed on the bolts that are included in the mounting kit;
on drains with the help of special clamps;
on a flat roof. The stops are fixed using a specially designed fixing kit under the doorway.

When attaching the autobox to the roof, special attention must be paid to its position. It should not be carried forward, or hung back. It is fixed with the help of mounting brackets that wrap around the crossbars from below and are inserted into special holes in the bottom of the case.

Providing aerodynamics and fixing the sides

Installing a homemade roof rack on the roof can greatly degrade the aerodynamic profile of the car, which reduces the stability of the car when cornering and increases gas mileage on open highways. To avoid this, it is necessary to fasten the front and rear racks structures under acute angle to the roof surface. This is achieved due to the difference in the length of the upper frame of the trunk and its base. The exact dimensions and angle of inclination are calculated during the design process.

aesthetic touches

In order for a home-made trunk to become a harmonious addition to the car, and not an incomprehensible structure on the roof, after welding it must be sanded, primed and painted. You can hide the mounting bolts with decorative nuts.

Soft boxing can be made original by printing some unusual pattern on the fabric. Such work can be ordered in advertising agencies specializing in advertising on car awnings.

Additional devices and devices

The forwarding luggage carrier has strong boards on which it is possible to mount additional equipment, for example: fog lights, vetkootboynik or additional antenna.

It is a pity that when buying a car, a roof rack is not provided. This is a very convenient design for transporting all kinds of things: from small and light, to heavy and overall, as well as strong-smelling. And it is not always possible to buy a ready-made home-made or factory trunk.

There is a good way out of this situation. Namely, to create a roof rack with your own hands. This version involves savings in the family budget. Another name for a homemade trunk is expeditionary. It cannot carry heavy and bulky cargo. It is designed for personal belongings, tents, skis and snowboards, mattresses and large umbrellas, as well as small furniture.
You can also make the most popular autobox. It is convenient in that it is protected from the environment even in bad weather and from theft. And if you make it a streamlined shape, then there will be no excessive fuel consumption.

How to make a roof rack with your own hands

In general, roof racks are divided into two types:

boxing;
arc-cross.

Benefits of expedition luggage carriers:

If you make a popular autobox yourself, it will be convenient in that it will protect you from rain in bad weather and from theft.

more functional;
contains many different things of any configuration;
holds large items;
protects the roof from damage from above;
does not block the driver's view.

Disadvantages of expedition luggage:

baggage weight limit;
fuel consumption increases;
difficulty in stacking a heavy load;
with improper fixation, there is a fear of losing part of the cargo;
reduced aerodynamics;
poor stability of the machine in a crosswind.

Transportation of oversized cargo

For luggage items, the shape of a basket with sides is suitable. For transportation of long things - a flat open platform.

To make homemade, you should carefully measure the linear dimensions of the roof. The luggage carrier must not extend beyond the roof in the area of the front glass or interfere with the doors. Ideally, it is best to follow the dimensions of the factory trunks calculated for these models. Dimensions can be found on the websites of manufacturers, or on the roofs of cars of acquaintances and friends.
Next, you need to determine the type of trunk. For luggage items, the shape of a basket with sides is suitable. For transportation of long things - a flat open platform.
Determining the number of mounts for a car roof rack with your own hands:

four support points are suitable for hatchbacks and sedans;
if the length of the roof is over 2.5 meters, then it is better to make six fasteners.

Homemade trunk with sides

Now you need to make drawings of the forwarding trunk with dimensions. You can also work according to the sketch of the factory model.
Of all the materials for the manufacture of a luggage structure, an aluminum alloy profile is best suited. It is easily cut, bends, does not corrode and is light in weight. The construction of steel will be heavy, which in turn will reduce the weight of the transported cargo.
You will need a frame made of a profile pipe with a section of 20x30 mm and a wall thickness of 2 mm. It is not advisable to use round pipes, as the cargo slides off them during transportation.
You will also need tools and components:

Of all the materials for the manufacture of a luggage structure, an aluminum alloy profile is best suited.

welding machine;
electrodes;
ruler;
roulette construction;
angle grinder;
discs for metal;
drill;
drill;
nozzle for cleaning welded seams;
a set of mounting components;
clamps for mounting mufflers;
mounting foam;
paint for metal (preferably the color of the car).

Drawing of a homemade trunk

After the drawing is ready, and the tools and components are purchased in full, you can begin to manufacture the cross member for the roof rack:

Determine the length of the cross. They must be the same in size.
Cut the profiled pipe into several parts to get longitudinal and transverse guides.
Weld parts of the trunk, clean the welding seams.
Seal them with mounting foam inside and out. Usually one bottle is enough.
After complete drying and hardening of the foam, grind it with a grinder. Initially, you need to make crossbars in the shape of a parallelepiped. Then, if desired, they can be given a rounded look. The main thing is that they look in relation to the car, like "relatives".
Then, for strength, cover the foam with fiberglass in 2-3 layers. It is advisable to take a fabric with a strength of at least 300 g / m2.
For attractiveness, the crossbars can be painted in any color (usually they take black, or the color of the car).

Manufacturing of fasteners

In the manufacture of the trunk, you need to remember safety precautions - it is impossible to load the car roof over 70 kg.

First way. Take a clamp for attaching a muffler from any car. This is a flat bracket on one side and an arc that goes around the pipe on the other side. Saw off everything else from a flat plate. Now it will tightly adjoin the crossbars and the roof rack arches.
The second way. Use threaded U-shaped brackets. Instead of nuts, fix the lambs, with which it will be very easy to unscrew and tighten.

Crossbar fastening

To attach the cross members to the rails, holes must be made in them. Measure them symmetrically on both sides, taking into account the holes in the mounting plates. Drill carefully.
Put the trunk tightly on the rails. If somewhere there is no snug fit, you can use rubber gaskets. Fasten securely with bolts and nuts. It is also necessary to remember about safety precautions. It is impossible to load the roof of the car over 70 kg.

Often, the prices for branded roof boxes are so shocking to car owners that some decide on grandiose experiments and try to make a box on their own. The most accessible material, more or less suitable for creating an imitation of a hard luggage box, is plywood. The fact that homemade boxing is nothing more than an imitation proves any crash test. The test video clearly shows that do-it-yourself roof boxing does not pass standard tests. A home-made plywood box on the roof literally shatters in those emergency situations where the factory one has every chance of remaining intact.

Cons of assembling a homemade plywood roof box

In addition to the very laborious manufacturing process from the creation of a drawing to the assembly of elements homemade boxes on the roof of the car also have the problem of calculating the final weight . To assemble such a "lego box" you will have to put quite a lot of fasteners on the joints. A set of hardware itself can weigh up to 3 kg. This is an additional load on the car, which is not available in polymer factory boxes.

The weight of painted plywood, stiffening ribs, adhesives and fasteners on the stitching of the elements of the box trunk, created by oneself, eliminates any hint of aerodynamics . Even attempts to copy the shape and proportions of the original box will not help to reduce and evenly distribute the weight of a homemade one. As a result, creating an aerodynamic car roof box with your own hands is as unrealistic as building a racing car in a garage.

Plywood, to put it mildly, does not have the properties of ABS plastic even after processing primers, automotive paints, yacht varnish, laminations and other attempts to protect a DIY roof box from external influences.

In addition to the difficulties of protecting against moisture, home-grown craftsmen want to make a roof box with their own hands at least a little like factory samples. In the overwhelming majority, such a task is beyond reality and handicraft box trunk does not look like elegant boxes developed by professional engineers.

You will have to make your own roof box opening system . At this point, the creative ideas of the "Kulibins" reach the use of furniture fittings, the removal of mechanisms from household appliances and other exotic methods of equipping boxes. Of course, you cannot count on the trouble-free operation of mechanisms that, in principle, are not designed for boxes.

A short review of the main problems of plywood boxing clearly proves that doing DIY work is unprofitable. However, there is an alternative to expensive boxes. The Autodream company has developed its own luggage box model in full compliance with progressive technologies. You can buy a high-quality box at a price that is almost equivalent to the cost of a home-made one, only without the risk of losing a car with a luggage box in the comfort and safety of operation.

I want to make something similar. The lower part will be made of an aluminum composite panel with longitudinal reinforcements made of an aluminum profile pipe, the upper part will be made of a banner fabric with full-color printing, I drew a drawing in size.
Here is the finished bottom part. Here are the amps
I gave the banner for printing - the layout is HERE))))
We are waiting for the banner, and this is how the zipper with the flap will be sewn on. Today we made the lower side with holes for rivets. On the front of the edges I decided to put two super bright LEDs. This was recommended to me by a truck driver. I asked him why? Answer: Tipo with this box 80% you will ride not in the city but outside it. Truckers also have lamps or diodes on the roof. This is so that when you drive at night and when light bulbs appear from behind a hillock in the distance, then people automatically turn on the dipped beam (Most people) And when they are not there, they switch only after the oncoming headlights appear. But while the headlights appear, those on the balls are bludgeoning the distant one.
Here is the banner Cut out We sew on sewing machine around the perimeter. Instead of ordinary threads, I took a fishing braid (POWER PRO braided cords are made in the USA from 100% SPECTRA FIBER microfiber) Sewing a lock. I sewed it from the side of the curb so as not to hang around on the road while parking and searching for things. Now we attach the banner to the base with glue (COSMOFEN CA 12) and additionally rivet the perimeter. Well, the stage of attaching the box to the roof has come. My main requirements for fastening are - reliability - ease of installation - cost - aesthetic appearance. The first thoughts were - to fasten with brackets with 2 nuts, a bolt through the trunk and ... any nonsense. I thought for a long time and have an idea. I took the JOKER mount as a basis . With the help of a grinder, cut off the excess and voila. We buy locknuts and bolts 80mm long.
Let's try it locally! And here they are ++ Aesthetic appearance + Reliability + Installation 3 minutes + Cost + Does not rust!
Now decided to bring to mind appearance. I painted the lower amplifiers black from the can
Boxing is ready!

www.drive2.ru

How to make a car roof rack with your own hands + photos and drawings

Every car owner once becomes too crowded in the car - for example, when he starts repairs and carries tiles and plaster in the car or rushes to the country in the spring with seedlings. It is most effective in this situation to place luggage on the roof of the car using a special device. However, prices for high-quality trunks range from several thousand to two to three tens of thousands of rubles. A simple and practical solution is to make a trunk with your own hands.

Why you need a roof rack

A roof rack is a must if you:

started repairs and independently transport building materials;
moving, transporting a large number of things;
are fond of outdoor activities, be it cycling, snowboarding, skiing, fishing, hunting, hiking, etc.

Roof rack - a minimalist solution for avid travelers

Types and photos of the most common designs

To get started, you should decide on the type of roof rack for your car, which is right for you. There are several types of structures:

If you have the necessary skill, patience, time and desire, you can make any type of trunk with your own hands. The most popular and cost-effective are universal and forwarding trunks. These are the ones most often chosen by car owners.

Before proceeding directly to the process, it should be noted that the owner of the car undertakes to manufacture the trunk at his own peril and risk and for possible consequences he himself is responsible.

And also pay attention to the fact that you are unlikely to need the trunk all the time, so you should consider making it removable and using it as needed.

Universal car trunk

It is better for an inexperienced craftsman to start by making the simplest type of trunk. In fact, you have to make two crossbars. For this you will need:

metal profile, for example, with dimensions of 20X30 mm and a wall thickness of 1.5–2.0 mm (ideally aluminum, since it is lighter);
muffler clamps - 4 pieces. With their help, the trunk will be attached to the roof (if there are roof rails);
mounting foam;
grinding machine;
fiberglass with a density of 300 g / sq. m.;
dye.

Step by step manufacturing

To make a roof rack in accordance with the parameters of the car and securely fix it on the roof, follow the algorithm below:

First, cut the crossbars. The length of the cross members must match the width of the vehicle body.
We cover the crossbars with foam both inside and out. The layer should be quite dense: this will allow the next step to give the crossbars the necessary shape.
After the foam dries, we grind it with a grinder. At the first stage, we give the profile the shape of a regular parallelepiped, and then we add design changes in order to improve aerodynamics, in particular, we grind corners.
Since the foam has a loose structure, the cross members can be additionally covered with putty for the car - so their surface will become smoother.
We wrap the crossbars with fiberglass in three layers.
We paint the crossbars and wait for drying.
At this time, we will be engaged in the manufacture of fasteners. In our case, we decided to take the path of least resistance and use muffler clamps. They need to be prepared - file the bottom of the clamp to get a flat plate for a tighter fit.
We drill holes in the crossbars. On each side should be two symmetrically arranged holes. The distance between them should match the "ears" of the clamp.
We fix the crossbars on the rails. In order not to damage the cross members with clamps, rubber gaskets can be placed at the points of their contact.

Video: features of mounting the structure on the Oka car

Expeditionary trunk type "basket"

The technology for manufacturing an expeditionary trunk will be an order of magnitude more complicated. In this case, you will need to first draw up a drawing. In addition, you can not do without a welding machine and the ability to handle metal.

Mesh base - a practical solution for expedition trunks

Construction drawing

Take as an example a homemade trunk for Chevrolet Niva. The trunk will be 163 cm long and 123 cm wide. 30x20 (approx. 6 p.m.).

Expeditionary trunk on the Niva according to this drawing, it is quite possible to do it yourself

The sequence of actions of the wizard:

We start manufacturing the trunk from the base: we cook the perimeter. Longitudinal guides - from profile 30X20, transverse jumpers - from profile 20X20.
We weld into the perimeter the bearing jumpers from the profile 30X20. For them, the platform will be attached to the rails.
We reduce the distance between the bearing jumpers by welding additional transverse ones from the 20X20 profile.
We make an arc that will be located in front in order to improve aerodynamics: we measure 5 cm from the edges of the profile and cut out a triangular sector, after which we bend the profile. We weld the arc from the outside of the perimeter.
To increase the strength of the structure, we fasten the jumpers together with sections of the 15X15 profile. If desired, lintels that are not load-bearing can be replaced with a metal mesh or stainless steel sheet.
We make boards. The profile is cut into pieces 6–10 cm long and welded to the base. If desired, they can be put on a thread - then the sides and the upper part of the trunk can be removed.
It's time for the top bar. In size, it should repeat the bottom one, but the side rails should be slightly shorter, and the posts connecting them to the base should be angled to improve aerodynamics.
We fix the trunk in the same way as described above. Important point: for even weight distribution forwarding trunk should be attached to six points.

If the car does not have roof rails, you will have to make the supports yourself from a piece of sheet metal. You can put it on brackets, but for this you have to drill the body.

The forwarding luggage carrier differs in the functionality increased in comparison with a usual luggage carrier. For example, fog lights can be attached to it - it is enough to weld the headlight mounting bracket to the inclined connector in the front (see point 7).

In addition, it is convenient to carry a shovel in the expedition trunk. You can fix it with a conventional pipe mount.

Video: construction fasteners on an SUV

Roof rack: pros and cons

We have already begun to talk about the benefits that roof racks provide to the car owner above. Now let's analyze them in more detail.

The advantages of a roof rack are many:

The most obvious plus, of course, is the extra space for things. So, on the roof you can easily place three bicycles or everything you need for outdoor recreation - a tent, an inflatable boat, fishing equipment, etc. And the capacity of seemingly quite compact boxes can be up to 300–800 liters;
it becomes possible to carry non-standard, for example, very long loads (like ladders, boards, pipes, etc.);
due to the fact that part of the luggage is moved to the roof, it becomes much freer, more comfortable and safer in the cabin;
The roof rack provides more even load distribution. So, if all the cargo is in the trunk, the car "sags". Because of this, it decreases ground clearance and there is a risk of tipping over.

Possible problems

Along with the obvious advantages, car roof racks have a number of disadvantages:

they, as a rule, negatively affect the aerodynamic properties of the car. An irregularly shaped trunk will create additional resistance to air flow, which means that the stability of the car will also suffer. This may also result in additional noise.
a car with a roof rack adds significant height, which means it will not be able to drive on sections of the road where appropriate restrictions are set.
the trunk itself, even empty, weighs from 1.5 to 15 kg or more, which increases total weight cars and hence fuel consumption. According to some estimates, an unloaded trunk increases gas mileage by 0.2 liters per 100 km in urban areas.

So, you have learned what roof racks are, got acquainted with their advantages and disadvantages, figured out how to make some of them yourself. Now you don't have to puzzle over how to place all the tents, spinning rods, backpacks and other equipment in the car - there is a place for all this on the roof of the car. All you have to do is relax and enjoy your vacation. Good luck on the roads!

carnovato.ru

Do-it-yourself roof rack on a car: we will tell you how to make it

Do-it-yourself car roof rack

There is a good way out of this situation. Namely, to create a roof rack with your own hands. This version involves savings in the family budget. Another name for a homemade trunk is expeditionary. It cannot carry heavy and bulky cargo. It is designed for personal belongings, tents, bicycles, skis and snowboards, mattresses and large umbrellas, as well as small furniture. You can also make the most popular autobox. It is convenient in that it is protected from the environment even in bad weather and from theft. And if you make it a streamlined shape, then there will be no excessive fuel consumption.

How to make a roof rack with your own hands

In general, roof racks are divided into two types:

Advantages of forwarding trunks:

If you make a popular autobox yourself, it will be convenient in that it will protect you from rain in bad weather and from theft.

more functional;
contains many different things of any configuration;
holds large items;
protects the roof from damage from above;
does not block the driver's view.

Disadvantages of the forwarding trunk:

baggage weight limit;
fuel consumption increases;
difficulty in stacking a heavy load;
with improper fixation, there is a fear of losing part of the cargo;
reduced aerodynamics;
poor stability of the machine in a crosswind.

Transportation of oversized cargo

For luggage items, the shape of a basket with sides is suitable. For transportation of long things - a flat open platform.

To make a homemade roof rack for a car, you should carefully measure the linear dimensions of the roof. The luggage carrier must not extend beyond the roof in the area of the front glass or interfere with the doors. Ideally, it is best to follow the dimensions of the factory trunks calculated for these models. Dimensions can be found on the websites of manufacturers, or on the roofs of cars of acquaintances and friends. Next, you need to determine the type of trunk. For luggage items, the shape of a basket with sides is suitable. For transportation of long things - a flat open platform.

Determining the number of mounts for a car roof rack with your own hands:

four support points are suitable for hatchbacks and sedans;
if the length of the roof is over 2.5 meters, then it is better to make six fasteners.

Homemade trunk with sides

Now you need to make drawings of the forwarding trunk with dimensions. You can also work according to the sketch of the factory model. Of all the materials for the manufacture of a luggage structure, an aluminum alloy profile is best suited. It is easily cut, bends, does not corrode and is light in weight. The construction of steel will be heavy, which in turn will reduce the weight of the transported cargo. You will need a frame made of a profile pipe with a section of 20x30 mm and a wall thickness of 2 mm. It is not advisable to use round pipes, as the cargo slides off them during transportation.

You will also need tools and components:

Of all the materials for the manufacture of a luggage structure, an aluminum alloy profile is best suited.

welding machine;
electrodes;
ruler;
roulette construction;
angle grinder;
discs for metal;
drill;
drill;
nozzle for cleaning welded seams;
a set of mounting components;
clamps for mounting mufflers;
mounting foam;
paint for metal (preferably the color of the car).

Drawing of a homemade trunk

After the drawing is ready, and the tools and components are purchased in full, you can begin to manufacture the cross member for the roof rack:

Determine the length of the cross. They must be the same in size.
Cut the profiled pipe into several parts to get longitudinal and transverse guides.
Weld parts of the trunk, clean the welding seams.
Seal them with mounting foam inside and out. Usually one bottle is enough.
After complete drying and hardening of the foam, grind it with a grinder. Initially, you need to make crossbars in the shape of a parallelepiped. Then, if desired, they can be given a rounded look. The main thing is that they look in relation to the car, like "relatives".
Then, for strength, cover the foam with fiberglass in 2-3 layers. It is advisable to take a fabric with a strength of at least 300 g / m2.
For attractiveness, the crossbars can be painted in any color (usually they take black, or the color of the car).

Manufacturing of fasteners

In the manufacture of the trunk, you need to remember safety precautions - it is impossible to load the car roof over 70 kg.

First way. Take a clamp for attaching a muffler from any car. This is a flat bracket on one side and an arc that goes around the pipe on the other side. Saw off everything else from a flat plate. Now it will tightly adjoin the crossbars and the roof rack arches. The second way. Use threaded U-shaped brackets. Instead of nuts, fix the lambs, with which it will be very easy to unscrew and tighten.

Crossbar fastening

To attach the cross members to the rails, holes must be made in them. Measure them symmetrically on both sides, taking into account the holes in the mounting plates. Drill carefully. Put the trunk tightly on the rails. If somewhere there is no snug fit, you can use rubber gaskets. Fasten securely with bolts and nuts. It is also necessary to remember about safety precautions. It is impossible to load the roof of the car over 70 kg.

Read on the topic:

mytopgear.ru

Making an expedition trunk with your own hands

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, it is quite possible to make an expedition trunk in the garage with your own hands.

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 body type of "coupe" or "sedan" will be forced to hire carriers if they need to buy building materials for a dacha or garage, because boards and pipes simply won't fit in the trunk. Even an ordinary bicycle can be put into the standard luggage compartment of far from 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.

The forwarding rack is installed on the roof of the car and is used to transport large items.

Such trunks can be divided into two categories:

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.

Autoboxes have a more aesthetic appearance and do not violate the aerodynamics of the car, but it is 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 yourself is almost impossible.

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 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 when empty installed trunk;
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 often travel, like to ride bicycles with 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.

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.

Roof rails are very convenient for attaching cross members, but not all cars are equipped with them.

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 the manufacture of the trunk will need thin-walled pipes of different diameters

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.

prepare the project of the forwarding trunk in accordance with all measurements

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.

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

Cut the metal profile according to measurements Apply mounting foam to the profile, then remove the excess and give the crossbars the desired shape Apply several layers of fiberglass and paint the structure in the desired color

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 make fasteners, cut off all the "lugs" from the muffler clamps and leave clean plates

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.

Install the crossbars in place with the fasteners

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.

To make a trunk of a similar shape, you will need the skills of welding metal structures

This method is best to resort to if you are transporting really bulky 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 anti-corrosion primer to the metal If desired, add construction mesh to the bottom of the trunk Install the trunk using special fasteners

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 solve 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.

With the help of a special fastening in such a trunk, you can transport construction equipment

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 forwarding trunk, and thereby save windshield from damage.

Vetkootboynik one of the sides are attached to the luggage structure

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 people install fog lights on the trunk, but the principle of giving 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.

lovers long trips it is interesting to learn how to make autoboxes on the roof of a car with your own hands. Modern machines for all their pluses, they have quite small trunks. Therefore, many drivers are forced to use various additional devices. Most often, autoboxes are used. They allow you to transport various goods on the roof. Thus, you can transport things without fear of getting them dirty or wet. Also, unlike conventional frame trunks, autoboxes are more aerodynamic. Types and types How to make car roof boxes with your own hands? First you need to decide on the type of trunk. The materials used and the complexity of the assembly depend on this. The final choice of variety is influenced by the cargo that is planned to be transported. Autoboxes differ mainly in the type of fastening. most familiar domestic motorists is a gutter. It can be found on many cars, it is located along the roof at the edges. Usually ordinary trunks are attached to them, this is done using clamps with bolts. Some models have roof rails. This allows you to install sufficiently voluminous autoboxes on the roof. There are special fasteners for completely smooth roofs. The boxes are divided into 3 groups according to their length:

Short- occupy about a third of the roof;
Medium- they are a little more than half the length of the roof;
Long- equal to the roof or slightly exceed it in length.

The choice here depends on your needs. If you plan to transport a small number of small items, then the short option is ideal. For trips with the whole family, it is best to use medium-sized trunks. Long ones are ideal for transporting skis and other similar equipment. How to do? First, decide on the method of attachment. This largely depends on the design of the base. Crossbars should end with fasteners. To clarify the appropriate type of fasteners, just take a close look at the car. After that, purchase the necessary elements. Light but durable material should be used for the base. Aluminum or duralumin channels are best suited. This allows you to make the design not only durable, but also lightweight. That will have a good effect on the economy of the car. Between themselves, the parts of the base are assembled on bolts. The result is reliable and, if necessary, can be quickly disassembled. Also, something is usually attached to the base to stiffen the load. Polycarbonate is best suited for this. You can use a composite aluminum panel. A collar should be made on the sides. It is usually made from the same that is placed on the base. It is attached either with special locks or rivets. It all depends on the material.

Any material can be used. Most often they use something like a tarpaulin. For greater aesthetics, you can take a banner fabric. She is quite flexible. At the same time, it does not transmit light and moisture. At the same time, you can order printing of drawings, which will make the car more attractive. Choosing the right lock is important. Keep in mind, being under the influence of snow and ice, it will freeze in winter. Therefore, when cutting fabric, provide a protective valve. You should also use zippers designed for skiers. Assembly. First you need to cut the fabric into fragments. Then they are sewn together. It is better not to use ordinary threads. Instead, it is better to use fishing braid or fishing line. This will give the seams more security. Lightning is best done from the curb. So it will be less polluted. And the unloading will take place more safely. After sewing the cover, a plate is placed in it, which gives rigidity to the structure. Attach it all to the crossbars. Autobox can be used.

Additionally Do not be too lazy to make a little highlight on your expedition trunk. To do this, a pair of white LEDs should be installed in front. They are connected to the lighting of the car. When the dipped beam is turned on, they will also burn. This is done for greater traffic safety. On a night road, a car with this design is visible much further. This is especially true of highways with a large number of descents and ascents. Oncoming drivers will switch to the near one in advance, which will save you from blinding. Conclusion. If you travel far and with a lot of things, then sooner or later you will have to attend to an additional trunk. That's when the question arises, how to make autoboxes on the roof of a car with your own hands. It's not that hard to do. It is important to choose the right material for boxing. And don't go wrong with the size. It is also important to take into account the requirements for fasteners, locks. It's good to add some extra space. As a result, you will get an autobox that is not inferior in performance to the factory one.

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