If you built a jig then welding it would be easy right off the bat... humm maybe i could mass produce these things lol...

 

You wont hear a peep from my rack. and i will put it up against any rack. Now in the future. Have you ever had on your jeep or seen another rack built with screws?

 

No Doubt, ive seen sheet metal screws hold up to some horrid abuse without ever comming loose.

 

hey warthog if i got a third stock roof rack cross bar and had the roof rack mounted in 6 places instead of 4 do you think that would spred out the weight enough for me to mount a 31" spare up there?

 

Yup,
That would work great. I was thinking about just buying two extra and throwing them up there so i would have 8 attach points. But with my 4 attach points, i have laid on top of the rack without anything creeking, cracking or breaking. But it would probably ease your nerves to throw one or two more cross bars up there. It would ease mine a little

 

ya thats what i was thinking, but i got a problem i cant figure out how to take the rails off a doner xj

 

I can't remember off the top of my head but i know some else on here knows, hopefully they will chime in for you.

 

You can take the end caps off the rails with a torx bit and slide the cross bars off.

 

I do not know how they perform nor will i ever. I seen one on a samurai before and i felt of it and it was weak, rusty, and around the 4 corners their was bends. It may have been built cheaply but i rather do it right the first time.

 

Well most corners are considered bends, anyway, Mine was built right and if you are ever down this way you can check it out and it will change your mind.

To the OP. I would deffinetly recommend building it using screws, rivits, or any other fastners. Once all the pieces come togethere. You won't need anything stronger.

Everyone also remember, The more weight you have up top the more chance you have of rolling it.

 

Absolutely true!

 

Well it would be a good option, but I don't have a welder easily accessible so self tapping screws are my best bet. It gives us mild do-it-youselfers a good jump start on a project.

 

Warthog i actually finished a rack out of 1" pipe and its very similar to yours, kind of copied you, hope you dont mind

i used all number 10 self tappers, 196 to be exact

i bend conduit for a living (some call me an electrician), so i made sure everything was perfect, no kinks in the 90's and if you take your time and know how to properly set a self tapping screw, it will be rock solid.

i considered welding the joints once i was all done, but when it was assembled i realized how solid it was.

 

I made mine a bit wider then warthogs, now im trying to figure out how to attact it to the rails lol...

 

well heres a questions to warthog or anyone else, what would you guys charge to build it up, tear it back down and send it out in a smaller box. since theres no welding required. and if there is some welding I can do that too.

Any takers.