Roof rails are an attachment to the roof of a car that gives it a unique appearance and enhances it. specifications... These accessories are used to mount additional luggage equipment. It can be:
- specialized box;
- basket on the roof of the car;
- mounts for bicycles, skis, snowboards, and other tourist equipment for recreation.
But before installing the trunk, box, or specialized mounts, you need to install additional cross members. They will be securely attached to the rails, and to them, respectively, the transported equipment. These crossbars for the trunk can be either purchased at specialized car dealerships or made yourself. Next, we will describe several ways to make do-it-yourself crossbars for roof rails.
Tools and materials for the manufacture of roof crossbars
Making crossbars for roof rails with your own hands will not be difficult. For their manufacture, it is necessary to take into account the features of each car, as well as the individual wishes of the motorist. The main "plus" of creating fasteners with your own hands is the price, since the purchased crossbars will cost several times more.
Also, do not forget about the strength characteristics. When transporting cargo, the main thing is that it does not fall and create an emergency. Therefore, it is also not worth saving on the quality of materials for the manufacture of crossbars for the trunk. Today, the cargo transported on the roof of a car can range from 60 to 110 kg.
To create crossbars for roof rails, we need:
- metallic profile;
- grinder, drill, welding;
- fixing material (bolts, nuts, washers);
- polyurethane foam;
- heat shrinkage;
- construction hair dryer;
- paint, brush.
Typically, the roof rails for installing the rack are two parallel straight lines that are fixed to the rails. During their manufacture, you need to take into account the shape of the roof, as well as its width. The material for them can be a metal profile made of light alloy materials, or a square pipe (metal thickness - up to 3 mm).
Cargo strap The cargo is fixed by means of:
- belt fasteners (if the cargo is transported directly on the crossbars);
- nets (if a basket is used);
- support or pressure clamps (for transporting skis, snowboards, bicycles).
Also, during the installation and removal of the crossbars, it is necessary to provide rubberized gaskets to prevent damage. paintwork car body. Below we will consider several options for creating crossbars with our own hands.
Homemade roof cross member options
Option number 1... Such creation of crossbars will be the easiest and will not take much time. In this case, we need:
Manufacturing process:
Option number 2... This option will not be as practical as the first, and will require breaking the integrity of the car's roof rails. So, we need:
The process of making crossbars with your own hands will be as follows:
This process of making and installing the cross members is recommended in case of continuous use. After dismantling the crossbars, it deteriorates badly appearance the car due to the drilled rails.
Option number 3... This option will be more practical, since the materials used in it have a more streamlined shape. Therefore, virtually no noise is generated when the vehicle is moving. But the maximum carrying capacity of these cross members does not exceed 60 kg. By slightly strengthening the method presented below, it will be possible to load up to 90 kg. But this will require additional costs. To make crossbars, we need:
The very process of making crossbars for roof rails will be quite simple. The main thing is to make the correct measurements and not be mistaken:
This crossbeam manufacturing process is fairly straightforward and does not require any special skills. Also, the advantages of these crossbars for installing the luggage rack are that they can be installed at different distances, depending on the transported goods and the make of the car.
Option number 4... In this case, it is necessary that there are specially designed mounting holes in the car rails. For the manufacture of crossbars for the trunk, we need experience in welding. We list the materials required to create crossbeams.
Do-it-yourself universal roof rack, you can make any size, for any car and use different mounting options.
Conventionally, it can be divided into two component parts:
luggage area
platform attachment posts
LUGGAGE AREA
The roof rack has two dimensions.
Length- the length of the steel bent unequal-flange channel (GOST 8281). We choose from the standard range.
We accept h = 32(mm).
Cut off the assortment of the required length.
With a constant step, along the entire length, we drill through holes with a diameter of ten millimeters.
We mill grooves with a diameter of fourteen millimeters, with a depth to the inner wall of the channel. The grooves will allow you to remove the radius of curvature.
Below, we drill through holes with a diameter of six millimeters for attaching the platform to the trunk racks.
Width- length of cold-deformed seamless steel pipe (GOST 8734). We choose from the standard range. Outside diameter - 14 (mm). Wall thickness - 3 (mm).
On both sides of the cut workpiece, we cut an M10 internal thread twenty millimeters long.
We connect pipes with channels
To do this, you can use screws with an internal hexagon.
BRACKETS
Consist of two parts welded together. Each part is manufactured from sheet metal with a thickness of 3 (mm). From the top of the rack, two through contours are cut.
The length of the groove allows you to adjust the platform relative to the rack.
The set position is fixed with bolts, nuts and washers.
The rack is attached to the car body with a special lock
using bolts, nuts and washers.
Car roof rack is an indispensable accessory for tourists and travelers, hunters and fishermen, as well as for all motorists who prefer active rest in the company of their four-wheeled friend, and at the same time do not want to occupy the space of the car interior with unnecessary things.
For the rest of the inhabitants, it will become a useful assistant for transporting things and building materials when moving to a new place of residence, repairing or traveling to the country. 
If the factory price seems overpriced, you can make it with my own hands from scrap materials. 
Where to begin?
Before starting work on making a roof rack for a car with your own hands, you should decide on the goals of its operation. 
The most common designs:
Universal trunk. Simple design with several crossbars and fixing brackets. Suitable for transporting bulky luggage and is installed on any car model. 
Expedition Trunk... Due to its more robust design, it is characterized by carrying capacity and spaciousness. It can be used to transport cargo weighing up to 200 kg and protect the car roof from damage. 
Bicycle holder. Designed exclusively for transporting bicycles with frame fasteners. 
Boxing. Fastened to roof rails. For the reliable preservation of the things transported in it, it is made of plastic or waterproof fabric.
After choosing the optimal type of structure, you can proceed directly to its manufacture.
Preliminary calculations
Drawing up a drawing of the trunk with your own hands begins with measuring the width and length of the roof of the car. If you plan to install a complex structure, then before starting work you need to determine the size and weight of the future trunk. 
It's also important not to forget about the basics of aerodynamics and design the front end to be more streamlined. This will reduce air resistance while driving and increase the soundproofing of the trunk. 
The drawing itself should consist of the following elements:
It should be remembered that when making a trunk on his own, a motorist must understand and accept all possible risks during its subsequent operation.
How to fix it?
The option for installing the trunk directly depends on the car model and the design features of the roof. 
On the roofs of the "classics" of a domestic manufacturer, as well as on old foreign cars, a longitudinal drain is provided, which is used to fix the trunk.
For this type of installation, metal stops with a clip are made or purchased. Such design feature car roof makes it possible to fix roof racks of different designs and dimensions
For modern models with longitudinal rails, you can use ready-made clamps for attaching the muffler or make a clip yourself. 
For this, a metal sheet is selected and bent in size. Holes are drilled in it for screw fastening to the trunk. 
Required tools and materials
After preliminary calculations, it is necessary to turn to the selection of materials and this process should be treated with all possible responsibility.
For example, a roof rack made of heavy materials, such as thick-walled steel pipes, will significantly increase the weight of the vehicle, and it will be costly and difficult to work with them.
When choosing a material, you should pay attention to aluminum or a thin-walled profile pipe, which have a low dead weight and do not require significant processing efforts. 
In addition to the material for work, you should attend to the following equipment:
If further painting of the finished product is expected, then this list can be supplemented with automotive paint.
Manufacturing process
For an illustrative example, let's take the manufacture of an expeditionary luggage carrier for a UAZ Loaf. It is distinguished by its large capacity, and in terms of cross-country ability it is inferior only to an all-terrain vehicle, which makes it great car long journeys to the most remote corners of the planets. 
Standard dimensions for a loaf rack:
These dimensions are considered standardized, but for optimal compliance it is better to carry out the measurement work yourself, because the dimensions of the roofs are different models differ, and the dimensions of the trunk itself, based on the needs, everyone calculates for himself. 
For the presented example, the required distance between the stiffeners is 57 cm, and the only longitudinal rib runs in the center. 
The assembly process begins by welding the lower frame with stiffeners. The next step the upper perimeter is welded. As indicated in the calculations, to reduce the aerodynamic load, the leading edge is made smaller and rounded.
Next, the guardrail is welded and welded to the lower frame. Supports for fastening and a netting are welded to it. 
The last stage is descaling, degreasing and priming. After drying, the finished product can be painted with automotive paint.
Do-it-yourself photo of trunks
It is a pity that when buying a car, there is no roof rack. This is a very convenient design for transporting all kinds of things: from small and light, to heavy and oversized, as well as strong smelling. And it is not always possible to buy a ready-made homemade or factory trunk.
There is a good way out of this situation. Namely, create a roof rack with your own hands. This version assumes savings in the family budget. Other name homemade trunk- expeditionary. Heavy and bulky cargo cannot be transported on it. It is designed for personal belongings, tents, skis and snowboards, mattresses and large umbrellas, as well as small furniture.
You can also make the most popular autobox. It is convenient in that it is protected from the environment even in bad weather and from theft. And if you make it a streamlined shape, then there will be no excessive consumption of fuel.
How to make a roof rack with your own hands
Generally, roof racks are divided into two types:
- boxing;
- arc-cross member.
Benefits of Expedition Racks:
If you make the most popular autobox, then it will be convenient because it will protect you from rain in bad weather and from theft.
- more functional;
- accommodates many different things of any configuration;
- accommodates large items;
- protects the roof from damage from above;
- does not obscure the view of the driver.
Disadvantages of an expeditionary trunk:
- limiting the weight of baggage;
- fuel consumption increases;
- difficulty in stowing heavy loads;
- in case of improper fixation, there is a fear of losing part of the cargo;
- reduced aerodynamics;
- poor stability of the machine in a crosswind.
Transportation of oversized cargo
For luggage items, the shape of a basket with sides is suitable. For transportation of long items - a flat open platform.
To make a homemade one, you should carefully measure the linear dimensions of the roof. The roof rack must not protrude beyond the roof in the area of the front glass or interfere with the doors. Ideally, it is best to follow the factory rack dimensions for these models. Dimensions can be found on manufacturers' websites, or on the roofs of friends and acquaintances.
Next, you need to determine the type of trunk. For luggage items, the shape of a basket with sides is suitable. For transportation of long items - a flat open platform.
Determining the number of do-it-yourself roof rack mounts:
- four pivot points are suitable for hatchbacks and sedans;
- if the length of the roof is more than 2.5 meters, then it is better to make six fixings.
Homemade trunk with bumpers
Now you need to make drawings of the expeditionary luggage rack with dimensions. You can also work on a sketch of a factory model.
Of all the materials for the manufacture of the luggage structure, an aluminum alloy profile is best suited. It is easy to cut, bend, non-corrosive and lightweight. The steel structure will be heavy, which in turn will reduce the weight of the transported cargo.
You will need a frame made of a profile pipe with a section of 20x30 mm and a wall thickness of 2 mm. It is not advisable to use round pipes, as the load slides off during transportation.
You will also need tools and components:
Of all the materials for the manufacture of the luggage structure, an aluminum alloy profile is best suited.
- welding machine;
- electrodes;
- ruler;
- construction tape;
- angle grinder;
- discs for metal;
- drill;
- drill;
- nozzle for cleaning welded seams;
- set of mounting components;
- clamps for fastening mufflers;
- polyurethane foam;
- paint for metal (preferably in the color of the car).
Homemade trunk drawing
After the drawing is ready, and the tools and accessories are purchased in full, you can start making the cross member for the roof rack:
- Determine the length of the transverse. They must be the same size.
- Cut the profiled pipe into several parts to obtain longitudinal and transverse guides.
- Weld parts of the trunk, clean out the welding seams.
- Seal them with polyurethane foam inside and out. Usually one bottle is enough.
- After the foam has completely dried and hardened, grind it off grinder... Initially, you need to make the crossbars in the form of a parallelepiped. Then, if desired, they can be given a rounded look. The main thing is that they look like "relatives" in relation to the car.
- Then, for strength, cover the foam with fiberglass in 2-3 layers. It is advisable to take fabric with a strength of at least 300 g / m2.
- For attractiveness, the crossbars can be painted in any color (usually black, or the color of the car).
Manufacturing of fasteners
When making a roof rack, you need to remember about safety precautions - you cannot load the roof of a car over 70 kg.
The first way. Take a clamp for attaching a muffler from any car. It is a flat bracket on one side and an arc that bends around the pipe on the other side. Saw off everything else from the flat plate. It will now fit snugly against the roof racks and roof racks.
Second way. Use U-shaped threaded staples. Instead of nuts, fasten the lambs, with which it will be very easy to unscrew and tighten.
Fastening the crossbars
To attach the crossbars to the rails, holes must be made in them. Measure them symmetrically on both sides, taking into account the holes in the mounting plates. Drill carefully.
Place the luggage rack firmly on the roof rails. If there is no snug fit somewhere, you can use rubber pads. Fasten securely with bolts and nuts. It is also necessary to remember about safety precautions. The roof of the car must not be loaded over 70 kg.
One of the most common problems for motorists is the lack of free space for transporting large or bulky cargo. To remedy this shortcoming, some manufacturers equip cars with additional roof racks. And those drivers whose car is not equipped with a roof rack can make and install it themselves. But in order for the result to meet all expectations, it is important to understand how and from what to make the structure.
The roof rack, located on the roof of the car, is designed to carry bulky goods that, for various reasons, do not fit into a standard trunk. Very often on the roof of a car vehicle the driver is instructed to carry bicycles, bulky suitcases, fishing tackle, and even building materials that are of great length, such as boards or skirting boards.
Not all owners need to install a roof rack. A clear need to install additional luggage space arises in such cases:
- Frequent journeys, long trips and travel "savage", involving the use of large travel devices and furniture;
- Engaging in active sports and recreation;
- Regular carpentry or renovation work.
A trailer can act as an alternative to the roof rack. However, to use it, certain driving skills and the mobile structure itself are required. Therefore, it is easier to use a roof rack.
There is no need to install a roof rack on a car if the car is used by the owner exclusively for movement.
Preparatory moments
Before starting the manufacture and installation of the trunk with his own hands on the roof of the car, it is important for the owner to complete a series preparatory work... These include:
- Selection of the most suitable type of construction;
- The choice of the main material from which the trunk will be assembled;
- Selection of the type of fastening that will be used for mounting the finished structure on the roof.
The final result of the work directly depends on the thoroughness of these activities.
Selecting the type of construction
Car roof racks are of two types:
- Lattice, or arcs-crossbars;
- Boxes.
Arcs-cross members allow you to transport cargo on the roof of the car different sizes... In addition, such a design is easy to make yourself. Trunk boxes, although they have a more attractive appearance, are notable for their small capacity. In addition, it is extremely difficult and very costly to make boxes on your own.
That is why, considering options self-made roof racks, it is best to opt for lattice structures such as an arc-cross member.
Material selection
When planning to assemble and install a homemade roof rack, it is very important to choose the most suitable material for the design. It should be borne in mind that the weight of the product can negatively affect the speed and maneuverability of the machine, as well as fuel consumption, significantly increasing it. Therefore, do not use heavy materials.
Light and soft metal alloys are the optimal material options for the trunk. Aluminum is ideal for these purposes, which also has protection against corrosion processes. However, this type of trunk will not come cheap. To significantly save and get good result works, you can use profile thin-walled pipes as a material.
Determining the type of attachment
Mounting a homemade roof rack on a car roof can be done in the following ways:
- Regular installation. It can be produced when the manufacturer has provided special mounting holes in the roof of the vehicle. In this case, the luggage compartment is fixed by bolting it to the body at several points along the perimeter.
- Universal installation. It is carried out by installing special fasteners in the holes of the gutters.
- Installation on roof rails. These structural elements are longitudinal side rails located on the roof of the machine.
The most convenient and gentle way for the car to fix the trunk is to install it on the roof rails. These items are usually made of plastic.
Manufacturing technology
In order to quickly, correctly and efficiently make a roof rack on a car roof with your own hands, it is important to carry out the work in the following sequence:
- Prepare everything necessary materials and tools.
- Draw up a drawing of the future structure, as well as the principle of its installation.
- Make a trunk according to measurements and a developed design drawing.
- Fix the finished roof rack using the selected method.
Before starting work, it is important to measure the roof of the car, on which the trunk will be installed. And when developing a drawing of a future trunk, take into account not only this, but also the geometry of the roof.
Required tools and materials
The main part, which cannot be dispensed with in the process of making a trunk, is a suitable metal. Also, in the process of work, the following components and accessories will come in handy:
- Welding machine;
- Grinder with attachments for metal cutting;
- Polyurethane foam;
- Clamps for car mufflers;
- A set of grinding tools;
- Fiberglass with a density of at least 300 g / m 2.
For the final stage of creating a trunk and ensuring its long-term operation, you will need car paint... The color of the paint can be any. However, the trunks that look best on the car are painted in the tone of the car body, as well as in silver or black.
Drawing
To create a drawing of the future trunk, you need to make a number of measurements:
- Measure the distance between the existing rails;
- Calculate the length of the roof and determine the dimensions of the indents from the edge.
Taking into account the weight of the metal components and the required load capacity of the trunk, it calculates the required amount of material, and also schematically depicts the appearance of the future structure.
After carrying out all the calculations, it is necessary to draw up an accurate drawing of the luggage rack for the car planned for production, with the dimensions of the parts marked on the diagram. In this case, the drawing must necessarily contain the following structural elements:
- General dimensions of the product;
- Length and location points of transverse reinforcing bridges;
- The height of the sides of the future design;
- Trunk bottom.
When developing a project, it should be borne in mind that roof racks, which have a rectangular or square shape, create significant air resistance during the movement of the car. Because of this, the aerodynamic performance of the car can be seriously affected. To prevent this from happening, it is recommended to make a trunk with a streamlined headboard.
Manufacturing
Roof rack making process passenger car with his own hands has the following sequence of actions:
- Carefully study the created design drawing.
- Trim the metal to create the trunk frame. The work is done using a grinder.
- From a suitable metal with a grinder, cut the elements that will later become the stiffeners of the product. If there is no need to transport very heavy loads, it is enough to prepare two longitudinal and transverse elements.
- Weld pieces of metal together so that you get two identical rectangles. One of them will be the bottom of the trunk, and the second is needed as a side.
- Strengthen the lower rectangle by welding stiffeners to it, at the same distance from each other.
- Spliced together the bottom of the structure and the side. This can be done by welding at the corners of rectangles, placed one above the other, and at several points on the sides, metal rods or tubes of a diameter smaller than the main structure.
At the end of welding, the metal is lightly sanded and painted in the color selected for the structure.
Car roof mount
To install a car rack on the roof of a car with your own hands, you will need rails mounted on the sides. If they are not there, these elements can also be made by yourself. This requires:
- Using a grinder, cut out two pieces of the same size from a metal pipe, suitable for the length of the roof.
- A generous layer of polyurethane foam is applied to the metal on all sides and left to dry completely.
- After the foam has hardened, with the help of grinding tools, the products are given the required shape.
- The resulting crossbars are covered with glass cloth in 2-3 layers.
- The finished roof rails are painted black or any other suitable color.
After that, the roof rails are mounted on the roof of the car using clamps for car mufflers. All unnecessary parts of the clamp are cut off without fail so that in the end only a flat plate is obtained on the railing. Further, symmetrical mounting holes are drilled in the rails on both sides. The prepared plates must be drilled at the same points. After these manipulations, the cross members are bolted to the roof of the machine. If the products do not fit snugly, a small rubber gasket can be placed between the plate and the railing.
The finished rack is attached to the roof rails using brackets. In the absence of crossbars and unwillingness to do them yourself, the trunk can be attached to the roof of the car directly. However, in this case, you will have to drill holes for the brackets in the car body, and fix the roof rack with their help.
For long-term and successful operation of a self-made trunk, the product must be periodically cleaned of road debris, sanded and repainted. Having chosen metal pipes as a material, the decorative and protective coating should protect the product from corrosive processes.
Also, in order for the trunk to serve for a long time, it is important not to overload it, but when filling it, make a careful distribution of the weight of the baggage over the entire area of the structure.
