custom roof rack

[downest]

Does anyone have a custom or unusual/large roof rack on a wagon? I have the factory one on my outback with the crossbars. I want to construct a large rack that spans most of the roof and is sort of a big metal bin where I can put all kinds of gear, like spare wheels, gas cans, chainsaw, portable welder, stuff like that. I don't want to weld to the car, I'd prefer to use something else as a base or some clips that hold to the factory racks.

So...

What is out there for already-made solutions?

What do other people have?

What is the weight limit of the roof?

What can I use as a base to make my rack?

Is there a good place to run wire through for lighting?

[T_F_E]

Does anyone have a custom or unusual/large roof rack on a wagon? I have the factory one on my outback with the crossbars. I want to construct a large rack that spans most of the roof and is sort of a big metal bin where I can put all kinds of gear, like spare wheels, gas cans, chainsaw, portable welder, stuff like that. I don't want to weld to the car, I'd prefer to use something else as a base or some clips that hold to the factory racks.

So...

What is out there for already-made solutions?

What do other people have?

What is the weight limit of the roof?

What can I use as a base to make my rack?

Is there a good place to run wire through for lighting?

I dont think there is already made solution

Lots of people like the yakima or thule racks

Yes, not sure what it is I heard 150lbs earlier but that doesnt sound right

Build off of existing rack?

Good guide for roof lights viewtopic.php?f=39&t=5752 (https://sl-i.net/FORUM/viewtopic.php?f=39&t=5752) On some trucks I have went down through the a pillar. Take note lights over 42 inches off the ground must be covered when on public roads

[downest]

They need like plastic covers, or just can't be on?

[T_F_E]

almost all lights come with the plastic covers, check your local laws. That is the general law though they have to be covered not just turned off. I mounted some lights off of my license plate and they work great check out my members ride thread

[1996Battlewagon]

Well, you could always build yourself a roof basket, and mount it on your stock rack. viewtopic.php?f=39&t=1401 (http://www.sl-i.net/FORUM/viewtopic.php?f=39&t=1401).

About the lights, I wouldn't worry so much about it. My lights mounted to my roof aren't covered. I just don't drive around with them on all the time.

[downest]

Thanks, that is what I want to do! I'm going to make mine slightly larger, I want to be able to carry a full set of wheels/tires up there plus more stuff, I was gonna make a bar that goes through them and bolts down. I didn't plan on driving around with the lights on all the time, but I don't want to get pulled over for not having covers on them or anything dumb like that.

Now to find some mesh stuff!

[Black Sunshine]

If you have your owners manual, then it should tell you the weight limit of the OEM rack. Yakima racks are very versitile. The weight limit probably isn't much higher. They don't offer a setup that would have room for a full set of wheels. Maybe the largest turtle they offer would hold them, but probably not. They make a baja style single spare holder. they make a basket, but it isn't very large(I think it's almost square). Welding something up like you see on a South American passenger bus would be your best bet for the massive rack that you desire.

You would need to find a welder that wouldn't rip you off or buy yourself one. The head liner would have to come out to attach the rack(I caught one on fire once). You could find the best structural spots to weld up to while it is out. Maybe you could make the rack structure replace the roof structure, then cut out a massive section of the roof and replace it with plexi or poly carbonate.

I have always wanted a SUV style hatch spare tire holder on my wagon. If you put three or four hundred pounds up there the cars gonna handle like crap. You also have to consider what kind of weight the car is rated for overall. A full set of wheels will probably max out the OEM rack's weight limit. Whatever you get make sure you get a faring, rack whistle will cause road rage.

[downest]

If you have your owners manual, then it should tell you the weight limit of the OEM rack. Yakima racks are very versitile. The weight limit probably isn't much higher. They don't offer a setup that would have room for a full set of wheels. Maybe the largest turtle they offer would hold them, but probably not. They make a baja style single spare holder. they make a basket, but it isn't very large(I think it's almost square). Welding something up like you see on a South American passenger bus would be your best bet for the massive rack that you desire.

You would need to find a welder that wouldn't rip you off or buy yourself one. The head liner would have to come out to attach the rack(I caught one on fire once). You could find the best structural spots to weld up to while it is out. Maybe you could make the rack structure replace the roof structure, then cut out a massive section of the roof and replace it with plexi or poly carbonate.

I have always wanted a SUV style hatch spare tire holder on my wagon. If you put three or four hundred pounds up there the cars gonna handle like crap. You also have to consider what kind of weight the car is rated for overall. A full set of wheels will probably max out the OEM rack's weight limit. Whatever you get make sure you get a faring, rack whistle will cause road rage.


I am a welder and I planned to make one, I like that reference to South American passenger bus, I think that best describes it :P I don't want to weld directly through the car, I would like to use the existing rails. I also don't have the owner's manual for the weight capacity, but I don't plan in ALWAYS having the other tires up there, just thought it might be cool once in a while :P

[outbacktweaked95]

the stock rack is easy to get off. al you ahve to do is pul on the endcaps and theyll pop off, at least they did on mine and then you have 8 already threaded holes. if your a welder all youll hae to do is make a rack out of pipe im doing mine out of conduit from lowes its cheap and easy to bend also is already coaded but is much cheaper than buying sticks of material. i looked at a local supplier from my shop when i was akng a break and it was about 100 for just my large thinwall peices of tubing. an estimate wth condit is about 60 bucks ive did some cad files on the rack im plannng to build if u want them pm me and ll send them to ya. Also i have 205/55/R16 on my car and there about 24 inches a peice. the width of the top of the roof of a subie station wagon is only about 3 ft so the tires would have to stick over if u did all of them on top as well as youd have a good bt of body roll with that much weight on its top.

[TheAngryPidgeon]

You should take one of those family bike racks:

http://www.maxxraxx.co.uk/images/index_family_boot_access_wide.jpg

Reinforce it a bit, since you can do the welding yourself, and store the wheels on the back. If you modified it right, you could probably go two wide and two deep, with the rubber to the sides of the vehicle, or go four in a row parallel to the direction of travel.

In all reality, you would probably have to heavily modify one of those racks to get it to support that much weight, and I'm not sure how adversely it would effect the handling, etc., but it's another idea for you to toy around with.

[T_F_E]

not sure if this has been covered yet but having something that big on the roof of your car will effect your gas mileage fairly bad