Almost every driver sooner or later needs an expedition rack. It is very useful for transporting large cargo that does not fit in the cabin or. It can be equipped with any class of transport, so it makes sense to make an expedition trunk with your own hands. It's much cheaper than buying a finished product, and it doesn't take much effort to create.

By using expedition trunk you can transport things that do not fit in the car

A question of merit

The main advantage because of which motorists equip their vehicle trunk - this is additional space. Also, thanks to this simple design, you can protect your vehicle from damage. Lanterns are also often installed on its surface for additional indication. True, welding an expeditionary trunk worsens the aerodynamics of the car, so it is better to attach it only when there is a real need for it.

First steps

Before making an expedition rack, it is important to determine the required weight. Modern designs are made of aluminum, as it is lightweight and highly durable. For trunks, this material is best used as a frame. Profile pipes that are quite lightweight are also a good choice. Stainless steel or regular metal will also work - they will have a greater impact on aerodynamics, but are easier to work with.

Preparing for work

There are no exact instructions for creating an expeditionary trunk, because each car owner himself chooses the functions that the structure should perform. Before starting work, you need to take accurate measurements of the roof. After this, you can start developing drawings, where a detailed view of the future structure is drawn.

To perform this operation correctly, you need:

• provide for the weight of the frame;
• place measurements;
• calculate the final weight.

It is important to take notes for all steps to ensure accurate dimensions of the structure. This is necessary, because overload cannot be allowed - it is important to correctly distribute all possible weight.

Start of welding

Having started work, all structural elements are welded together in the shape of a rectangle. Along the inner perimeter of the finished figure, ponds are attached to the middle of the finished frame. To avoid sagging on the platform, you can add several ribs inside the entire area (in the resulting free space).

Such ribs are made of iron. The result should be something like a lattice, which is arranged in a parallel manner. To further strengthen the roof rack, a pipe with a square profile is installed. This will be enough to ensure maximum stability.

High-quality aerodynamics

Thanks to this quality, the speed of the car and its resistance to wind friction are ensured. To improve this quality, a special arc is used. To do this, measurements of the material are taken, taking into account an overlap of 5 cm for the edges. Triangular sectors are cut out at the bending points, which are then folded. After this, all that remains is to weld the finished arc to the structure.

It is important to take care of the quality of the boards. For their fastening, special holes are used to insert a bushing of a certain diameter. When making the sides, you need to cut 6.5 mm posts (usually 8 pieces are enough), which will take part in the installation. One of the important elements of the trunk is the mounting pin. To set it up you need to do the following:

• 2 holes with a diameter of 8 cm are drilled;
• a pin is installed in the resulting space;
• welding is performed;
• you need to cut the required amount of thread;
• the finished pin is scrolled into the holes.

After these procedures, the side crossbar is made upward. It bends according to the same principle as the frame. To secure it, the bushing is welded into the bend for the side crossbar, and part of the stud is attached to the front beam. The rear crossbar is welded in a similar way.

Aesthetics are just as important

Having completed all the work, you will notice that the finished structure does not have a very attractive appearance. To solve this problem her . First, it is important to clean and degrease the entire platform. After this, you need to prime the metal so that the trunk does not become rusty in future use. It is better to choose a primer that can withstand exposure to salt solutions.

The coating should dry for at least 24 hours. After that you can start painting. The best option would be to use enamel. After hardening and checking the satisfactory appearance, the trunk can be attached to the car on the roof rails.

Making an expedition trunk allows you to get additional space for transporting things. In addition, it is perfectly equipped with fog lights or a radio antenna. Any motorist with basic welding skills can do this.

If you want to design an expedition rack, focus on the purpose of its use. If you need it to transport large items, then you should not skimp on ribs and crossbars, because they will protect the car from risk.

It is a pity that when purchasing a car, a roof rack is not provided. This is a very convenient design for transporting all kinds of things: from small and light to heavy and bulky, as well as strong-smelling. And it is not always possible to buy a ready-made homemade or factory-made trunk.

There is a good way out of this situation. Namely, create a roof rack with your own hands. This version involves savings in the family budget. Another name for a homemade trunk is expeditionary. It cannot transport heavy or bulky cargo. It is intended 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 because it is protected from environment even in bad weather and from theft. And if you make it streamlined, then there will be no excessive fuel consumption.

How to make a roof rack with your own hands

In general, roof racks are divided into two types:

• boxing;
• arc-crossbar.

Advantages of expedition luggage racks:

If you make a popular car box yourself, it will be convenient because it will protect you from rain in bad weather and from theft.

• more functional;
• holds a lot of different things of any configuration;
• holds large items;
• protects the roof from damage from above;
• does not obscure the driver’s view.

Disadvantages of an expedition rack:

• luggage weight limit;
• fuel consumption increases;
• difficulty in packing heavy loads;
• if secured incorrectly, there is a fear of losing part of the load;
• reduced aerodynamics;
• poor vehicle stability in cross winds.

Transportation of large cargo

For luggage items, a basket shape with sides is suitable. For transportation of long items there is a flat open platform.

To make a homemade one, you should carefully measure the linear dimensions of the roof. The trunk must not extend beyond the roof in the area of ​​the front glass or interfere with the doors. Ideally, it is better to follow the dimensions of the factory racks designed for these models. Dimensions can be found on manufacturers' websites, or on the roofs of cars of acquaintances and friends.
Next you need to determine the type of trunk. For luggage items, a basket shape with sides is suitable. For transportation of long items there is a flat open platform.
Determining the number of mounts for a car roof rack with your own hands:

• four support points suitable for hatchbacks and sedans;
• if the roof length is over 2.5 meters, then it is better to make six fastenings.

Homemade trunk with sides

Now it is necessary to make drawings of the expeditionary trunk indicating the dimensions. You can also work from a sketch of a factory model.
Of all the materials for the manufacture of luggage structures, an aluminum alloy profile is best suited. It is easy to cut, bends, does not corrode and is lightweight. A structure made of steel will be heavy, which in turn will reduce the weight of the cargo being transported.
You will need a frame made of a profile pipe with a cross-section of 20x30 mm and a wall thickness of 2 mm. It is not advisable to use round pipes, since the load will slide off them during transportation.
You will also need tools and components:

Of all the materials for the manufacture of luggage structures, an aluminum alloy profile is best suited.

• welding machine;
• electrodes;
• ruler;
• construction tape;
• angle grinder;
• metal discs;
• drill;
• drill;
• nozzle for cleaning welds;
• set of mounting components;
• clamps for muffler fastenings;
• polyurethane foam;
• metal paint (preferably matching the color of the car).

Drawing of a homemade trunk

Once the drawing is ready and the tools and components have been purchased in full, you can begin manufacturing the cross member for the roof rack:

1. Determine the transverse length. They must be the same in size.
2. Cut the profiled pipe into several parts to create longitudinal and transverse guides.
3. Weld the trunk parts, clean the weld seams.
4. Seal them with polyurethane foam inside and out. Usually one bottle is enough.
5. After the foam has completely dried and hardened, grind it down with a sanding machine. Initially, you need to make cross members in the shape of a parallelepiped. Then, if desired, they can be given a rounded appearance. The main thing is that they look like “family” in relation to the car.
6. 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.
7. For attractiveness, the crossbars can be painted in any color (usually black, or the color of the car).

Manufacturing of fasteners

When making a trunk, you need to remember safety precautions - you cannot load the roof of the car over 70 kg.

First way. Take a clamp for attaching the muffler from any car. This is a flat bracket on one side and an arc that goes around the pipe on the other side. Saw off everything else from the flat plate. Now it will fit tightly to the crossbars and to the roof rack arches.
Second way. Use U-shaped brackets with threads. Instead of nuts, attach wings, with the help of 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 trunk tightly on the roof rails. If there is no tight fit somewhere, you can use rubber gaskets. Securely secure with bolts and nuts. It is also necessary to remember about safety precautions. The car roof cannot be loaded with more than 70 kg.

The need to make an expedition trunk with your own hands arises sooner or later for every driver involved in the transportation of large cargo that is inconvenient for placement in the cabin. As you know, many who have an SUV often go on trips and it happens that the standard trunk does not accommodate everything they need. This becomes another reason to install an additional roof rack.

Every motorist understands that buying a ready-made trunk is a significant blow to the wallet. While making an expedition trunk at home will be a budget-friendly and profitable solution.

Suitable materials for making an expedition rack

Having decided to make a trunk with your own hands, it is important, first of all, to determine its actual weight when designing it. Modern models of “expedition vehicles” are made using especially durable aluminum, which is characterized by low weight and good technical performance (performance, durability, strength, flexibility, tearing, etc.).

As you can see, aluminum is The best decision when choosing a source material as the basis for a future product. Another option would be profile pipes with thin walls - they are also lightweight. And the third, simplest option is ordinary metal (in strips) or stainless steel. They are somewhat heavy, but easy to handle. It will not be difficult to make and install such a trunk on a UAZ with your own hands. After all, it is the cars of companies such as UAZ and Niva that are most often subject to independent modifications by their owners.

If you decide to make a trunk for a loaf with your own hands (or for a Niva), then a thin-walled profile pipe may also be useful for these purposes. For a loaf, ferrous metal or stainless steel is usually an excellent solution. There are plenty of options for choosing material for constructing a trunk. Much depends on the preferences of the car owner and the functions that the trunk will need to perform.

Main stages of work

With the right approach, you can successfully produce a professional trunk - high-quality and visually attractive, just like a purchased product. It will differ in that the car owner will assemble a frame structure based on his own needs and the functional purpose of the car. In general, the creation of a roof rack from any material is carried out according to a single scheme, in several stages.

Preparatory calculation work

When starting to create an external trunk, you should measure the roof and decide on the placement of supports. Since the dimensions of each car are different, it is necessary to measure everything yourself and make accurate calculations, especially when arranging an expedition trunk for the Niva. After this, the design of the future product is thought out: a drawing is drawn and the weight of the trunk as a whole is calculated.

You can carry out all the preparatory activities correctly only if you know the following information:

• made dimensional parameters;
• possible frame weight;
• the most probable weight of all elements of the trunk.

Ending preparatory work should be marked not only by drawing up a detailed drawing, but also by marking on it all the data obtained during the measurement. In this case, you will have to work a lot with your hands and head. After all, only a responsible approach to the implementation of the task will make it possible to produce a trunk of such a design and fasteners that will withstand enormous loads.

From words to deeds: we carry out welding work

Having made the blanks according to the drawing, they are welded together in the shape of a rectangle. In this case, along the entire internal perimeter of the resulting figure, ponds are fixed opposite opposite points in the middle of the frame. To prevent sagging of the resulting platform during loading, it is recommended to add 2-3 stiffeners to the resulting free plane inside the platform at equal intervals.

The ribs are made from profile iron. As a result, you usually get a kind of lattice frame with running parallel lintels. To strengthen the structure itself, a profile pipe with pre-prepared square-shaped cells is used. Thanks to these steps, it will be possible to make a truly reliable roof rack with your own hands.

Ensuring aerodynamics and fixing the sides

When thinking about the aesthetics and aerodynamics of the luggage structure, it is worth putting an arch in front. To do this, measure the required length of the material, with an overlap of 5 cm at the edges. In the bending areas, a triangular sector is cut out and folded. Thus, the arch for the front base of the trunk is ready. All that remains is to attach it to the structure, cut it to size and weld it. Also, jumpers are immediately welded to the arc.

The best option, of course, would be removable jumpers, because there are different cases. To attach the sides, holes are made into which bushings of the appropriate diameter are inserted. They are scalded in such a way that the profile does not bend when the bolts are tightened. After this, the sides themselves are made: the posts are cut to the required length (usually 6.5 cm) in the required quantity (about 8 pieces).

To arrange the mounting stud, the following steps are performed:

• two holes of 8 cm are drilled;
• a pin is placed in them;
• the part is welded;
• the required amount of thread is cut from it;
• The pin is screwed into the existing holes.

After this, the side upper crossbar is constructed. At the front, the workpiece is bent in the same way as the front frame. The paired element is done the same way. To attach the upper front crossbar, a bushing is welded to the bend of the side crossbar, and a piece of the stud is welded directly onto the front beam itself. The arrangement of the rear crossbar occurs in a similar way.

If there are doubts about the strength of the manufactured structure, and there is no desire to create the trunk anew, then it is worth welding several reinforcements in addition to the stiffeners. Then the expedition trunk will definitely be able to withstand any additional loads.

Aesthetic touches

When making a trunk for a Niva with your own hands, it is important to complete the manufacturing process, namely to paint the finished product. To do this, first clean the platform from scale and burrs. Then the metal is degreased and primed to avoid rust formation in the future. The best option is to prime the surface with a zinc-containing primer that can withstand the effects of salt solutions.

The drying period of the structure should take at least a day, but it is better that the drying lasts two days. After a long waiting period, you can begin painting the trunk. Usually enamel is used for these purposes. After painting, you can put closed decorative nuts on the trunk in the places where the bolts are attached. Install the trunk on the car yourself using roof rails.

Additional devices

In addition to the fact that the arrangement of an expeditionary trunk is necessary to ensure the interior of the car free space, it also allows you to solve a number of related and important problems. The use and installation of additional equipment with a wide variety of operational capabilities will help to give the roof rack other functions.

Additional equipment options:

• fog lights are additionally installed on the expedition trunk, which will make the road more illuminated;
• The radio antenna installed on the trunk will provide additional comfort when driving;
• You can attach a hijack and a shovel to the inner/outer sides of the trunk - they can come in handy on the road;
• You can install branch guards on the expedition trunk, which ensure the safety of the windshield from possible damage when driving through the forest (the arrangement of the trunk itself helps protect the roof of the car from a possible tree falling from above).

Thus, the conclusion suggests itself that every motorist who decides to solve the problem of lack of space for transporting goods and the safety of the car can make a trunk with their own hands. A carefully thought-out and well-calculated trunk will allow you to transport cargo of significant weight and size. With accurate technical calculations, it will not create vibration or whistling noises during high-speed driving.

(function(w, d, n, s, t) ( w[n] = w[n] || ; w[n].push(function() ( Ya.Context.AdvManager.render(( blockId: "R-A -136785-1", renderTo: "yandex_rtb_R-A-136785-1", async: true )); )); t = d.getElementsByTagName("script"); s = d.createElement("script"); s .type = "text/javascript"; s.src = "//an.yandex.ru/system/context.js"; s.async = true; t.parentNode.insertBefore(s, t); ))(this , this.document, "yandexContextAsyncCallbacks");

How to make a roof rack for your car yourself?

The problem of free space in the trunk worries every car owner. If you like to go on long trips with your whole family or on trips with friends, then you cannot do without an additional roof rack.

This type of trunk is called expeditionary, because you can’t put very heavy objects on it, but those things that you will need during the trip - tents, fishing rods, folded bicycles, sets of clothes, and so on - all this can easily be placed on the roof rack.

Another popular type of trunk is the autobox. Its main advantage over the expedition one is that all your things will be protected from bad weather, and the car box itself has a streamlined shape and will not affect the aerodynamic properties of your car too much.

Cars these days rarely come with roof racks. Although there are standard places for their installation, as well as roof rails on station wagons.

You can order from specialists or buy a custom-made trunk that will fit your car in size, but all this will be quite expensive. Those people who have skills in working with metal can make such a trunk themselves if they have all the necessary equipment. necessary tools.

Making a roof rack with your own hands

Material selection

First of all, you need to decide on the material. It is clear that the best choice- it's metal. But you need a metal with low weight and excellent strength characteristics.

The best option is aluminum, since it is light in weight, easy to work with, it is quite durable and is not afraid of corrosion.

You can also use a profile thin-walled tube; they prefer to install it on domestic SUVs - LADA Niva 4x4 or UAZ Patriot.

Very cheap option- this is sheet stainless steel, it is quite flexible and durable, however, its disadvantage is its weight, which is definitely greater than that of aluminum and metal profiles.

Measurements

Once you have decided on the type of metal, you need to take accurate measurements. This will help you calculate the total weight of the future structure, its approximate cost and, of course, the amount of materials.

(function(w, d, n, s, t) ( w[n] = w[n] || ; w[n].push(function() ( Ya.Context.AdvManager.render(( blockId: "R-A -136785-3", renderTo: "yandex_rtb_R-A-136785-3", async: true )); )); t = d.getElementsByTagName("script"); s = d.createElement("script"); s .type = "text/javascript"; s.src = "//an.yandex.ru/system/context.js"; s.async = true; t.parentNode.insertBefore(s, t); ))(this , this.document, "yandexContextAsyncCallbacks");

It’s best not to just measure the length and width of the roof, but to immediately draw up a project:

• frame;
• jumpers that are used to strengthen the structure;
• sides;
• load-bearing panel - it will be the bottom of your trunk, and will also strengthen it.

You can come up with additional elements - make the front side of the car streamlined, so as not to greatly disturb the aerodynamics.

Let's get started

If you have a detailed plan and scheme of work, then you can consider that the job is half completed.

1. First, the profile is cut using a grinder according to the drawn up diagram.
2. Then the perimeter of the expedition trunk is welded - you will get a rectangle of a certain size.
3. The perimeter is reinforced with the help of longitudinal jumpers, which we also weld to the resulting base. For greater reinforcement, the longitudinal jumpers are connected to each other, creating a lattice base - the bottom of your trunk.
4. A rectangular trunk is not very beautiful, it can spoil not only aerodynamics, but also appearance your car. Therefore, an arc is usually welded to the front part, which is made from the same metal profile.
5. Then they begin to manufacture the sides of the trunk. To do this, cut metal stands approximately 6 centimeters long. It is worth noting that the sides are usually made removable, that is, these racks are best not simply welded to the base, but mounted on a thread. To do this, holes are drilled in the base, into which bushings are then welded. Bushings are needed so that when tightening the bolts the metal profile does not deform.
6. The racks are welded to the top crossbar, which in its parameters repeats the base, with the only difference being that the side crossbars - left and right - are usually made a little shorter, and the front two racks connecting the crossbar and the base are installed at an angle so that your trunk does not look like an ordinary metal box, but followed the contours of the car. The front arc, by the way, is also used for this purpose.
7. Now that the trunk is almost ready, you need to start painting it and attaching it to the roof of the car. In order for the paint to stick well, you first need to prime all surfaces well and let the primer dry. Then we apply paint, preferably from a spray can - this way there will be no drips and it will lay down in an even layer.
8. There are many ways to attach such a trunk - if you have roof rails, then they can easily support the weight of the entire structure, and it is usually 15-20 kilograms. If there are no roof rails, then you will have to drill the upper part of the body and install the trunk on special brackets. Some cars have special standard places - recesses for fastening. If you wish, you can find various types of fasteners in stores that will allow you not to drill your car.

Advantages and disadvantages of expedition racks

The most important advantage is the additional space for transporting any things you need. The trunk also provides excellent protection against dents and overhead impacts.

You can find many other examples of roof racks. Some people just install a few cross rails to which you can attach whatever you want. Also, fog lights are usually installed on such trunks and a radio antenna is attached. If you're heading off-road, the roof is a great place to store essential tools like a shovel or hijack.

However, there are a number of disadvantages:

• deterioration of aerodynamics;
• fuel consumption increases - even small cross rails can lead to an increase in consumption in the extra-urban cycle by half a liter;
• sound insulation deteriorates, especially if the fastening is not fully thought out;
• If weight is not distributed correctly, handling may be affected.

It is because of these shortcomings that it is advisable to make such racks removable and use them only when necessary.

In this video you will learn how to make a roof rack on your car yourself.

Many drivers are faced with the problem that it is not always possible to transport everything they need due to the limited space of the car. Moreover, if it is a large and oversized cargo, then it is generally impossible to place it in the cabin. The way out of the situation could be a do-it-yourself roof rack.

Today there are a large number of different ready-made options in stores, but their cost is quite high. If you don’t want to spend extra money and are willing to devote a little time and effort, then making a roof rack can be quite simple. This will require a certain set of tools and materials, and we will describe the process of constructing the structure and its features in our article. Thus, you can completely solve the problem of lack of space for transporting things or cargo.

Pros and cons of a roof rack

The roof rack has many advantages. The most basic thing that emerges from its tasks is the creation of additional space for transporting some cargo and things. In addition, the trunk can protect the car from damage to its upper part, and also serve as a basis for installing additional lights or an antenna. For those who go off-roading, a rack can be useful for securing shovels and other tools. Overall, this is a very useful device.

Of course, there are also significant disadvantages. Firstly, the design on the roof slightly worsens aerodynamics, which in turn leads to an increase in fuel consumption by up to 1 liter. Secondly, if even minor errors were made in the calculations or manufacturing, then noise insulation and, in some cases, controllability may deteriorate.

Trunk material

First of all, after you decide to make a trunk for your car yourself, you will need to choose the source material. Usually, the best option considered metal. However, in this case, it is necessary to find a material that will have low weight, but at the same time have the highest strength.

These requirements fit perfectly:

• Aluminum;
• Profile tube;
• Stainless steel.

Aluminum is probably the most suitable option for several reasons. Firstly, it is very light. Secondly, it is resistant to external influences and is not susceptible to the negative effects of corrosion. Thirdly, it is very easy to work with it and form the necessary structures.

An alternative to aluminum is a profile tube with a thin wall. In most cases, for domestically produced SUVs ( UAZ Patriot, Lada Niva 4×4) a roof rack is installed from this very material. The cheapest option for a car is a stainless steel trunk. The sheets became very strong and at the same time flexible. However, a significant disadvantage of this type of material is its weight - it is much greater than that of a profile tube or aluminum.

Design measurements

When you have decided on the type of material that you will use for the trunk, then you next need to move on to making measurements and calculations. This way, you can clearly determine the weight of the future product, the approximate price and, of course, how much and what you need when building a trunk for a car.

It is necessary first of all to determine such indicators as the length and width of the entire roof. Moreover, you can even create a project in the form of a plan and drawings, which will include:

• The supporting panel (the trunk itself, or rather its bottom);
• Frame;
• Jumpers (special amplifiers for the structure);
• Boards.

In addition, you can come up with various additional details at your discretion. For example, this could be a special lining on the front part of the trunk, which will prevent strong resistance to oncoming air.

Manufacturing process

So, the materials have been purchased, the plan and design have been completed, which means that half the journey has been completed. Now we need to proceed to the most important thing - the actual construction of the trunk for the car. So, the process of building it is done like this:

• We cut the metal into the required sections according to pre-prepared patterns using a grinder;
• Using a welding machine, we form the perimeter of the future structure, taking into account the dimensions of your car;
• To strengthen and increase the reliability of the product, it is necessary to additionally weld longitudinal jumpers, which can also be fastened together (you will get a kind of lattice - the bottom of the trunk);
• We weld an arc to the front part of the structure, which will serve to improve aerodynamic performance and reduce air resistance, as well as to create a more attractive appearance;
• We create the sides by cutting small metal plates 6 centimeters high (as a rule, they are made removable, that is, they are installed on a thread, holes are drilled and bushings are installed, and not welded to the main structure);
• We weld the racks and top crossbars together so that the shape of the trunk blends harmoniously with the car and does not look like a metal box.

That's all, the roof rack for the car is ready. However, the work does not end there, as it still needs to be painted and installed. Before painting, treat the surface with a primer and leave it to dry for a while. After this you can apply paint. It is advisable to use a regular spray can, as it allows you to achieve good durability and does not create drips.

When it comes to attaching a roof rack, there are several options and it all depends on your car. For example, some machines have special recesses that will serve as mounting points, which is very convenient. Other models do not have special places, so you will have to drill the roof and install the structure using special fasteners. By the way, if your car has roof rails, then they can serve as the basis for installing the product, since its weight is light. Today, the market offers a large number of different types of fastenings that will allow you to avoid the process of creating holes in the roof of your car.

So, a roof rack is necessary for some people. If you are just thinking about making it, then weigh the pros and cons, and then make a decision. Overall, this is a very useful accessory for your car.