Custom Angled Rack Using 1030 Extruded Aluminum

[ggdillon]

I've been trying to find the perfect rack that matches the angles of the gladiator, is adjustable in height to allow 18' canoes to clear my soft top, fits with my tonnea and allows my cargo rack just above the tonneau. I've looked high and low and all commercial options have some significant shortfall.

I've sketched up a custom hybrid rack that isn't perfect either, but hits all the criteria. It's a hybrid of Xtrusion Overland (it uses 1030 extruded aluminum), the VooDoo VRS Canoe Rack (it mounts to my existing VRS rails), and Yakima Overhaul (is adjustable height).

Anybody have any thoughts before I go looking for quotes for the brackets?

This is the base rack that would mount to my VRS Rails

When spring comes, I'd add the adjustable height canoe racks, keeping them low for daily drives and raising them up when it comes time to haul the boats.

And it matches the angles of the gladiator:

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[nanook12]

I’d go for a better quality aluminum than 1030!

 

[mx5red]

Having done some of this already, It would probably be easier to just order overland extrusion’s rack. You could adapt your riser plates to it and have less things to do on your own.

 

[Sigz]

I have the VRS 22" rack from Kbvoodoo and modified the back ends of the rack to allow my tri fold tonneau cover to fit/open.

I'm actually in the process of enclosing the rack with some of VRS accessories and ordering some 8020 t slot extrusion to create a rear gate that opens/closes/locks to allow for more storage for longer camping/hunting trips.

 

[ggdillon]

just order overland extrusion’s rack

Yeah.... just modifying the xtrusion overland is a good option. I'd still have fair bit of modification with the different width, but the fit and finish would certainly be better than something I designed myself...

 

[ggdillon]

I have the VRS 22" rack from Kbvoodoo and modified the back ends of the rack to allow my tri fold tonneau cover to fit/open.

Thanks for that photo. One of my main issues with just going with the VooDoo Kayak Rack is that it doesn't match the angles of the truck; it angles in much farther (it does seem to match most of the other trucks on the market that aren't as "upright" as the gladiator). At least I thought it did.

Now looking at your photo straight on from the back makes me think that maybe that's less of a deal-breaker than I thought. I do have some tall items that sit on a cargo deck just above the tonnea and I thought that extra inward angle and the thickness of their bent-metal uprights might prevent me from storing them there.

Do you think you could do me a favor and measure the distance between the uprights on your rack? Like this:

 

[Wolf Island Diver]

I was just watching a recent The Story Till Now https://m.youtube.com/channel/UC_QteyvNZKtK5qPWlPbrl-Q and at one point one of the trucks with some kind of rack (not one of trucks with a cap) goes over a bump and you see their whole rack, racking back and forth from side to side. I have no idea what brand it was but it was simple uprights and some cross members. It was sketchy af.

The issue with these racks is that there’s maximum force applied to the exact area that uses a mechanical interface; the locations where the uprights bolt to the cross member. You can demonstrate this with force vector diagrams. You end up relying solely on the number and tightness of the bolts to keep the whole assembly from racking back and forth as you move over the road and there’s going to be a tendency for the holes to want to round out over time. It’s far worse off road where the whole truck is twisting and your multiplying the forces with acceleration in multiple directions as the truck moves over obstacles.

The better designs move the interface from the corners inboard with a one piece upright and corner, e.g. Leightner. They also change the orientation of the joint so that the bolts that attach the uprights to the cross member are vertical. The rack then doesn’t rely on the shear strength of the bolts and quality of the holes to stay together. You can also just weld the cross member to the uprights. Better racks have bracing in the opposite direction from the corners of that upright/crossmember interface to the center of the bed at the cab side (Leightner), or just really massive uprights (Yakima) or heavy tubular ones (commercial ladder racks).

Take a look at a lot of these racks static, dynamic and off road dynamic weight ratings. A lot of them are surprisingly low, especially the off road dynamic ratings if they even list them.

 

[ggdillon]

there’s going to be a tendency for the holes to want to round out over time.

You make a good point about that with these bolt-together racks. Hadn't thought about that part.

And while I think my overall loading is relatively light and i'm only driving some rutted dirt roads I did manage to destroy the yakima rack and the roof of my old tacoma just carrying kayaks and hitting some mud holes.

 

[Sigz]

Thanks for that photo. One of my main issues with just going with the VooDoo Kayak Rack is that it doesn't match the angles of the truck; it angles in much farther (it does seem to match most of the other trucks on the market that aren't as "upright" as the gladiator). At least I thought it did.

Now looking at your photo straight on from the back makes me think that maybe that's less of a deal-breaker than I thought. I do have some tall items that sit on a cargo deck just above the tonnea and I thought that extra inward angle and the thickness of their bent-metal uprights might prevent me from storing them there.

Do you think you could do me a favor and measure the distance between the uprights on your rack? Like this:

Sorry for the late reply.

The length of the inside of the top = 44 7/8

The length of the inside of the bottom = 60 3/8

 

[ggdillon]

Sorry for the late reply.

The length of the inside of the top = 44 7/8

The length of the inside of the bottom = 60 3/8

Thanks! Much appreciated!

 

[KB Voodoo]

Thanks for that photo. One of my main issues with just going with the VooDoo Kayak Rack is that it doesn't match the angles of the truck; it angles in much farther (it does seem to match most of the other trucks on the market that aren't as "upright" as the gladiator). At least I thought it did.

Now looking at your photo straight on from the back makes me think that maybe that's less of a deal-breaker than I thought. I do have some tall items that sit on a cargo deck just above the tonnea and I thought that extra inward angle and the thickness of their bent-metal uprights might prevent me from storing them there.

Do you think you could do me a favor and measure the distance between the uprights on your rack? Like this:

Stayed tuned for our new system,I think it's exactly what you're looking for.

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