DIY Aluminum Extrusion T Slot Rack for BAK Revolver x4s

[TheLunk]

Alright. So, Life happens and I just got my rack put together... Pretty happy with the results.

Here's a few pics:



I'll post up some details if anyone is interested...

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[TheLunk]

If anyone is wondering, here's the components I used.

Extrusion was all ordered through tnutz.com. I catch a break on shipping because they're only about 100 miles from me. Invoice at the bottom.

Hardware:

spot-weld nuts:

https://www.amazon.com/gp/product/B07TK14BW3/ref=ppx_yo_dt_b_asin_title_o09_s00?ie=UTF8&psc=1

socket head cap screws (from grainger):

https://www.grainger.com/product/22...l&gucid=EMT:10101010:SKU:CSM-348&emcid=NA:SKU

and these are the extra corner braces I added:

https://www.amazon.com/gp/product/B00M7BRWSI/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

Added split washers to everything to try and keep things together, but if I find anything starts to back out I'll go back with some blue threadlocker.

Product	Quantity	Price
EX-1530-BLACK - 1.5" x 3" BLACK Smooth T-Slotted Aluminum Extrusion Length (in): 24 Fractional length: 0.000" Machining for one end.: No machining Machining for other end.: No machining	4	$98.00
EX-1530-BLACK - 1.5" x 3" BLACK Smooth T-Slotted Aluminum Extrusion Length (in): 60 Fractional length: 0.000" Machining for one end.: No machining Machining for other end.: No machining	2	$121.00
15 SERIES - BLACK PLASTIC END CAP – BLANK - 1.5'' x 3'' Size: 1.5'' x 3''	12	$11.40
(CB-015-K-BLACK) 15 Series 4 BLACK Hole Inside Corner Gusset MOUNTING HARDWARE: NO HARDWARE REQUIRED	16	$104.80
Subtotal:	$335.20
Shipping:	$38.17 via Ground (UPS)
Payment method:	Credit Card (Stripe)
Total:	$373.37

 

[gstipton]

Meant to post this here.

Joined the extrusion club. I'm just starting with the basics because you know... need a way to hang those Christmas lights.

The real plan is to build it out more to mount and transport camping gear for trips with my kids in the spring. Right now having fun thinking about what to do next and what to make next.

I'd like to angle it in slightly, partly for aesthetics and partly so if I mount something on the side it doesn't stick out to the side as far. Considering making some brackets for the bottom with a slight angle and using an elbow joint from TNutz to join the extrusions.

 

[mx5red]

I decided to cut down the height of my rack. After a while I realized I’m not likely going to carry anything flat on the rack, which is why I originally planned it at/above cab height.
Pretty much anything I’d put up there whether kayak/surfboard/tent whatever is going to sit on a carrier so would be raised another few inches above the crossbars. Plus, it just never quite looked right to me.
So I cut the posts down 4.5”, from 23” to 18.5.” I think it looks much better and will still accomplish what I want to.
Before:

After:

 

[legend007]

LOOKS GREAT!

 

[SAReis]

Well, unfortunately neither the support on bakflip.com or BAK industries themselves could get me information on what fit their rail. A bit disappointed that they did not have any recommendations on t nuts or t bolts that would fit and just told me to essentially buy a rack that advertises compatibility with their cover.

I ended up hitting my local hardware store and found what they called "spot weld nuts" that looked like they would work. Bought all that they had (only enough for one of the rails) and some stainless hardware. These work significantly better than the upside down t nuts that came with the corner brackets. They fit well and with a half inch bolt the rack slides very easily when loosened and snug when tight.

Since the hardware store couldn't tell me when they would get more in (and didn't have them available online) I found what I "think" are the same ones on Amazon. Once I confirm this I'll post up a link to everything I bought.

These fit perfectly for me. Nice and snug.

https://www.amazon.com/dp/B08PL3XQ1...AY1OGTVY&psc=1&ref_=list_c_wl_lv_ov_lig_dp_it

 

[Sarge.Jave14]

Just got all the parts in and put it on yesterday. Extremely happy with how it turned out.

I was having trouble finding a rack that fit my needs. Requirements were:

- Low as possible while still allowing room for the Revolver x4s to open.
- Utilize the t slots (be able to adjust and slide forward/back)
- Easy to take on/off
- Carry lightweight items (my main purpose is to hold 2 bikes)
- Budget of around $500 or less
- (bonus) height adjustable

I decided to go the DIY route since I couldn't find anything to fit my needs. This led me down the path of aluminum extrusion.

Cost was way under budget, being a bit under $250 after tax and shipping (I had all the material arrive cut). I also have some smaller 1.5" legs if I want the rack lowered to just above the tonneau cover (obviously it doesn't open at that height though). Rack feels very stout and actually feels like it reinforces the tonneau cover rails so they flex a bit less.

Should be testing with my bicycles in the coming weeks (rain is in the forecast this weekend). I have two older yakima racks that I plan to use with this.

What’s the dynamic and static load weight?

 

[arskemp]

What’s the dynamic and static load weight?

I don't have any formal calculations or testing on that. When I was reading other project involving extrusion (usually it was for racks on top of SUVs or campers) their was a general consensus on max "desirable" deflection. I then looked as some generic deflection calculators for my bikes weights and locations (most common scenario for me) and then added a bit of safety factor and I was under that. Unfortunately, I don't really have any formal math on any of that, but it should be easy to calculate yourself. This doesn't cover fore/aft movement though, which is another concern (that could also be improved with larger corner brackets or running it with the shorter legs which is what I typically am doing anyways).

At the higher height I've jumped up and down on the center of the track as well as stood on it with both bikes mounted. That being said, I usually run it at the lower height (so that it is not viewable in the rear view mirror when not in use). I've had my bikes on it more than a couple dozen times at this point without issue.

In summary, the closest thing I have to a rating is putting my bikes on it, shaking it, and remarking "that aint going nowhere".

 

[Sarge.Jave14]

I don't have any formal calculations or testing on that. When I was reading other project involving extrusion (usually it was for racks on top of SUVs or campers) their was a general consensus on max "desirable" deflection. I then looked as some generic deflection calculators for my bikes weights and locations (most common scenario for me) and then added a bit of safety factor and I was under that. Unfortunately, I don't really have any formal math on any of that, but it should be easy to calculate yourself. This doesn't cover fore/aft movement though, which is another concern (that could also be improved with larger corner brackets or running it with the shorter legs which is what I typically am doing anyways).

At the higher height I've jumped up and down on the center of the track as well as stood on it with both bikes mounted. That being said, I usually run it at the lower height (so that it is not viewable in the rear view mirror when not in use). I've had my bikes on it more than a couple dozen times at this point without issue.

In summary, the closest thing I have to a rating is putting my bikes on it, shaking it, and remarking "that aint going nowhere".

thanks for the info. my plan is to DIY like you did and go about 8in high legs. Planning to put a RTT (roughly 120lbs empty). possibly 3 post (overkill?). i have not yet picked up the bed cover as i am still doing more research on what crossbar will work or what diy is best for the plan.

 

[AmosMoses]

This does t look very safe to me given how thin the aluminum is that your mounting plate clamps up against. Iam guessing it's .125 thick.

 

[mpboxer]

Hey all, for all you running this setup how is your Bak Revolver holding up to the added weight on the t-slots?

There's not much to the support brackets for the Tonneau, but I imagine most of the weight is distributed over the bed sides/rails.

Thanks,
Mike

 

[More4dan]

Just got all the parts in and put it on yesterday. Extremely happy with how it turned out.

I was having trouble finding a rack that fit my needs. Requirements were:

- Low as possible while still allowing room for the Revolver x4s to open.
- Utilize the t slots (be able to adjust and slide forward/back)
- Easy to take on/off
- Carry lightweight items (my main purpose is to hold 2 bikes)
- Budget of around $500 or less
- (bonus) height adjustable

I decided to go the DIY route since I couldn't find anything to fit my needs. This led me down the path of aluminum extrusion.

Cost was way under budget, being a bit under $250 after tax and shipping (I had all the material arrive cut). I also have some smaller 1.5" legs if I want the rack lowered to just above the tonneau cover (obviously it doesn't open at that height though). Rack feels very stout and actually feels like it reinforces the tonneau cover rails so they flex a bit less.

Should be testing with my bicycles in the coming weeks (rain is in the forecast this weekend). I have two older yakima racks that I plan to use with this.

GREAT BUILD! Thanks for posting, this is exactly what I want to add to my truck.

I did some quick calculations of the load capacity of the cross bars. I haven't done anything with the uprights or joints but the cross bar is likely the limiting factor. Use at your own risk.

Using 1515 4 sided slotted material and a point load in the center (worse case):
312 lbs static and 156 lbs dynamic per cross bar

Evenly distributed loads:
624 lbs static and 312 lbs dynamic per cross bar

This is using 60% of the maximum yield stress for the material. I have calcs. for 1530 material too if anyone is interested.

 

[2020 SCRAMBLER]

Can someone post up exactly what profile (part#, size, etc.) of 80/20 you are using on top of the bed rail and exactly how you’ve secured it to the Trail Rails? Thanks!

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