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Making a roofrack - anyone else want one too ?

Posted: Tue Jul 17, 2007 12:27 pm
by Griffin
Having used brackets for surfboards and adapted roof bars to fit, I have decided a roofrack is the way to go for large bulky but light things. Been looking on ebay and occasionally they appear (and look good) but they are quite expensive and don't really do what I wanted.

So the brief:

1) Mounted roof using the 4 x captive threads already on Bongo's roof (I dont want the additional gutter ability as it would encourage even more stuff to be put up there)
- NB I have seen roof bars with no supporting feet, sure they are OK for intended use (surfboard ?) but i wanted something more substantial than that so this will have metal 'feet' to help spread the weight and provide lateral stability.
2) Strong enough for some extended use but light enough for me to fit on my own.
3) Ability to put a variety of 'stuff' on it - think camping chairs, wetsuits in bags, etc. Decided a 1" mesh base was the way to go.
4) Have the ability to put a bike carrier onto it (something that is tricky to do with the original spacing. Yes I know I'll probably need a ladder as well for that)
5) Possibility of fitting a roof box to it should I change my mind about wanting one.

Thankfully I have a mate who has some welding gear etc. We came up with an idea and I drew a plan (with rough dimensions) as a start.

The build is now underway (see pic below). Main frame is compete so just some rear legs and feet to be fitted.

Looks a bit crude but once the finishing touches are done and painted I think it'll look great.

Hoping to have it completed by the weekend so I can use it for my 2 weeks camping holiday :D Exact height off the Bongo roof and the size of the feet to be decided 'onsite' with much umming and arring no doubt.

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It occurred to me that if successful (and I see no reason why it wont be) that others may be interested. Thought I'd see what the reaction was.

Let me know and I will post more pics when it's finished and fitted.

Posted: Tue Jul 17, 2007 12:36 pm
by mikeonb4c
Promising looking design. My only thoughts would be:

1) If it can at least rest some of the load on the roof gutter (doesnt have too fasten to it) then it would provide insurance against heavy loadings which you will sooner or later be tempted to put in a useful carrier like that.

2) Is it made of alloy. I'd be concerned about the wieght of it and, perhaps more importantly, rust issues if not. Also, trying to lift it into place if made of steel and heavy.

Good luck - you might have a market for the right product.

Mike 8)

Posted: Thu Jul 19, 2007 2:24 pm
by neepboy
I like it alot!!!!

Posted: Thu Jul 19, 2007 9:57 pm
by mikeonb4c
All quiet on the Griffin front. I think he's off having a wet holiday somewhere 8)

Roofrack and things

Posted: Fri Jul 20, 2007 1:14 am
by johnzbenson
It looks good and well constructed. I would pay particular attention to the feet assemblys so that the captive threads that you fasten into do not get "rocked" over time and loosen off. I wonder what the safe working load is of a bongo roof. does anyone know.
I think if I was making up some sort of carrier and i wasnt carrying Surf boards Skis/ Iron boards or similar I would devise something that bolted on the back of the bongo, somebody on here already did that with a roof box I think. Perhaps worth a thought for your next project!

Posted: Fri Jul 20, 2007 11:20 am
by Griffin
Hi Guys, been busy working and then finishing the rack ready for hols. Finished the welding last night (well I watched as a mate did it - cheers Carl :-) ), used good size feet to help support and I am really chuffed. It is as solid as a rock, you can easily rock the whole Bongo with no problem at all - probably not recommended apart from initial testing :)

I was expecting some additional road noise but in honesty I am not sure I can hear any difference compared to normal, certainly the phone kit etc could still be used as normal (usually a good indicator on other cars).

Didn't get home until 0100am thismorning so no time for pics.

Still needs a good painting but in terms of strength and stability I am chuffed. It weighs about 10 KG which I know is a bit heavy but, the roof does raise easily enough with a final bit of encouragement at the end of travel (same as others on here with roofboxes).

It looks pretty good as well, overall height of Bongo when fitted (obviously with nothing on it) is 217cm so not too intrusive.

Looking at the pics I posted it does look huge, in real life it looks really in proportion (from memory about 135 longx120 width). If I get chance I'll post some pics with it fitted and the loaded before I set off on Sunday.

With regard to mounting storage on the back (and at the risk of hijacking my own thread :!: ) I ususally use a Bak Rak with a 'garden cushion box) mounted on it for wetsuits etc. This time we are taking 4 bikes instead so carrying additional stuff there isn't an option.
There is a pic (on a Volvo not a Bongo on their website
http://www.bak-rak.com/images/IMG_4973.jpg )

Thanks for the comments so far, I'll keep you posted.

Posted: Fri Jul 20, 2007 12:39 pm
by mikeonb4c
Interesting griffin. I was going for a bak rak until I went for the trailer option instead. How do you find it overall, and where did you get your garden cushion box from as I couldnt find one locally at all! 8)

Roof rack ready to go

Posted: Sat Jul 21, 2007 2:48 pm
by Griffin
Bit of a rush job but my roofrack is ready to go. Very pleased although strapping stuff down (given the height) was a bit of an issue. May look at the solutions others have tried for that.

Currently holding 2 x adult and 2 x childrens camping chairs, 1 coat stand, a winbreak, 4 boogie boards, wetsuts for all and a camping gazebo. Hmmm sounds quite a lot now I think of it.

Off on hols tomorrow - roofrack means I can fit everything else in :D

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Posted: Sat Jul 21, 2007 3:19 pm
by ICB
Looks really good Griffin, lovely job :)

I want one, we're in the middle of packing up for 3 weeks in Ireland and it's going to be a nightmare getting everything in. :evil:

Posted: Sat Jul 21, 2007 10:59 pm
by Scott & Gillian
Looks very good and proper Griffin!
Let us know how it performs after your holiday!

Posted: Sat Jul 21, 2007 11:07 pm
by mikeonb4c
Very nice looking piece of kit Griffin - well done. 8)