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Old 04-13-2013, 05:05 PM
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aluminum roof rack

I'm looking to build an aluminum rack to go over my trucks camper shell "snug top". the bed is ~6.5' long i would like to make the rack 10' long, with it hanging over the cab. i really need to keep the shell to keep my tools dry but hate my ladders hanging out the back. the most that will be up there is 3 ladders and maybe some pvc and conduit. it dose not have to hold a ton of weight but would like to to be strong enough that in a pinch i could use it. will aluminum work what size tube pipe or angle would i need. i would like to mount my go-light and a ham antenna on the front, and some reverse light on the back. i was thinking of using 6061 t6 pipe or angle what size or what other aluminum would you think would work better and what filler wire? would mounting it to the top be good or do i need to run it down the sides to the bed rail.
i will post a pic of the truck when i can get one.
ford f-250 99 CC SWB

thanks matt
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Old 04-13-2013, 10:32 PM
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You could use 1" square tubing 1/8" wall.
Use the 6061 filler.

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Old 04-14-2013, 10:14 AM
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ok i did not know if 1" would be strong enough to work.
thanks
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Old 04-14-2013, 11:30 AM
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Going by what you said that you only plan on putting ladders and some PVC pipes 1" will be plenty strong enough as long as you use at least 1/8" wall thickness.

Square tubing is easier to work with too.
If you want it stronger you can fabricate a scissor truss style side rails and add more cross members to make it allot stronger.

https://www.google.com/search?q=alum...rp1JvDnkLyM%3A


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