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3 minute read
The Chronicles of Rabfan: Roof Rack
Compliments of rabfan @ www.vwvortex.com
Apparently I got drunk and promised some folks I'd make roof racks. I'm starting to think rum might be bad for me.
Anyway, Roof Rack manufacturing DAY 1;
First off, here's the raw material. I use 3/8" schedule 80 pipe for the side rails and 3/8" Sched 40 for the rest. I have to use the heavy gauge stuff in order to get nice bends. The thin wall stuff kinks in my crappy pipe bender.
I start with the outside rails since they are the the most work.
Cutting the pipe;
Making the bends;
Hammering the ends flat old school style. Shed 80 pipe is super strong.
The feet!
Profile cutting the straight sections using my super expensive hole cutters which break on occasion. I drove 60km today to buy 2 extra 5/8" bits in case I broke another one.
The product welded up;
Trimming down the nut serts on the lathe
Making the holes for them
Installing them
Chasing the threads after welding;
Will provide a nice hidden fastener;
Outside rails done!
That's enough for today.....
