The Chronicles of Rabfan: Roof Rack - by rabfan

By rabfan
( 2 )

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.....



Comments