Tell me the Pros and Cons of making my own roof rack

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KneesUp

Guru
Right. Well.

I have a car with some roof bars. And lots more camping equipment than will fit inside it that needs moving 400 miles this summer. Bikes will go on a bike carrier on the tow bar that the previous owner of the KneesUp jalopy had fitted. Thanks, previous owner.

Roof bars are - it strikes me - not very useful on their own. You need an 'accessory' in order to carry anything. In this regard, the old roof racks of the 70s and 80s were much more useful. However, Thule (which I think is Swedish for 'they will pay anything') charge £300 for a rack that will attach to your bars, and apart from that there doesn't seem to be much choice.

I do have a roof bag, but it's capacity is nowhere near big enough for the amount of guff that will need to be carried. I currently use it to store the tent poles in the loft, and they pretty much fill it on their own. I could hire a roof box, but it seems like a bit of a waste of £40 ... and so ... I wondered about making my own roof rack.

The plan is to make a sort of basket for the roof, into which I could place the tent fabric (Lordy that's a big bag -and it's 35kg too) and some of those plastic boxes with things like duvets (we're soft, ok?) and chair covers and blankets for around the camp fire - bulky light stuff, basically - and the tent fabric (if I can get it up there)

I can't weld, but I've discovered 'Tube clamp' which is basically scaffolding, but you can get it in thin tubes (just over an inch across) It's comfortably strong enough (265kg load over a 1 metre span and 900kg load per joint)

http://www.themetalstore.co.uk/products/tube-clamp - no link to this company (or tubeclamp)

So the idea is to make two rectanlges with the three way elbows at the corner, and join them with 25cm uprights, then lay two more lengths across the bottom rectangle, giving me a basket with four bars across the bottom to load things on to, and a nice guard rail thing to stop it falling off (and for me to attach straps to)..

Obviously the rack will be heavy (18.49kg based on the dimensions I'd need - tubeclamps give all the weights) but my car has an 80kg limit, which still gives me 60kg+ of luggage up there.

Does this sound like a good idea? Something I should tell my insurer about? Something the BiB might be interested in? Or just an ludicrous excuse to play Meccano?
 
Where abouts are you mate? I have a set of roof bars and a box you could buy/ borrow.
 
OP
OP
KneesUp

KneesUp

Guru
The cons are that it'll fall off or fail, with all the dire consequences that would follow.
The Thule ones are just attached with U bolts - and the tubeclamp stuff is way stronger than Thule too - of course if any rack fell off it'd be bad news, but this is less likely to, I'd say (I'd put eight u-bolts on I reckon - most roofboxes attach with four)

Or do you mean that if it failed it would be bad news because it was home made and so my insurers might get awkward?
 
OP
OP
KneesUp

KneesUp

Guru
Where abouts are you mate? I have a set of roof bars and a box you could buy/ borrow.
Thank you, but I've nowhere to store a roof box. I could dismantle my tubing roof-rack and store it easily, but a box wouldn't fit anywhere I'mm afraid - that was why I bought the bag.
 

Beebo

Firm and Fruity
Location
Hexleybeef
The police and your insurers can get very angry about unsecured loads.
What would you do if it fell of on the motorway? I imagine you have a much better excuse if you bought it rather than if you made it yourself.
 

Archie_tect

De Skieven Architek... aka Penfold + Horace
Location
Northumberland
Yes....I was thinking about liability.
Your car insurance company would be very, very quick to disassociate themselves from the liability of an accident involving following cars and lorries caused by a home-made roof box and clamping system falling off.... makes you blanch just thinking about it. But then that's what they do, avoid risk...

My cousin had a proprietary carrier loaded with 2 bikes that fell off the back of her estate car on the M1- it took months to settle and she vowed never to put bikes on her car ever again.
 
I don't think the police would have an issue with it, as long as it seemed well secured. If you thought it was, we would think it was - if it fell off, that's proof enough it wasn't! A traffic officer with a particular expertise may correct me...

If be more worried about the insurance company. If ring them and ask a careful question... I. E. Rather than "I'm making my own rack from scaffolding..." I'd ask "I'm looking at roof box options and just wondered if you put any limitations on then under my insurance - I. E. Weight or certain safety standards required?".
 
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Not only that but weight on top of a car makes a big difference to handling or can do. Even if the roof will take it, you may be surprised how different it feels in corners or on uneven surfaces. So plan carefully. Not the same thing but years ago I made my own blocks to take the front fork of my bikes attached by a QR. Worked a treat.
 

Dave 123

Legendary Member
I lost a roof box once on the A38 travelling to Exeter from Plymouth coming down the hill near Trago.

The roof box was empty, I couldn't be arsed taking it off and there were strong winds.

BOOM!

The bottom half snapped at the front roof bar. I felt sick as that and all the top half landed on the carriageway behind me, cars veering.

Whatever you do, make it safe!
 

marknotgeorge

Hol den Vorschlaghammer!
Location
Derby.
I'd suggest two different ways of securing the rack to the bars - say U-bolts and a metal cable. Try to make it so that if something does fail, the only car at risk is yours.
 
OP
OP
KneesUp

KneesUp

Guru
I'd suggest two different ways of securing the rack to the bars - say U-bolts and a metal cable. Try to make it so that if something does fail, the only car at risk is yours.
Good idea - I have two bike locks made of really heavy chain - I could wrap those around the roof bars and the roof rack.
 
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