Thread: Defender custom aluminium roofrack mounts

Ok, so this morning I cleaned up the shed, because I believe you work in crap you produce crap. And the first job was to get drill and tap all 8 holes. Simple enough, and now all the mounts are sitting up on the car.

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I have now cut the upper part of the mount that goes from the basket to the mount itself. Only problem is I cant figure out how to do it. Can't clamp it as its on an angle. And I don't have a block and tackle to hold basket at right height......any ideas? Might have to get some guinea pigs around to hold it whilst I weld it haha

Hi Austravel.
My 130 came with an alli roof rack.. It's very similar to the one you have made. Here's the mounting system on mine. Might b of interest to u. Cheers, Simon.

Hey sitec. That was similar to one of my original designs. Only prob is the actual mount I wanted all aluminium aswell. As aposed to bolting the mount to the rack. And it was a right pita to tig weld aluminium that was thick, yet the pieces were small. If I made it from steel it would have been sweet. But I do like the look of yours.

Ok so the upper mounts were cut and grinded back for welding. Also the basket needed to be grinded. Now I have sore arms from grinding above head height haha

The uppermount size up.

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And this is how she looks all tac'd up.

And this is how it looks tac'd up

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Well the racks all finished. Came up pretty good, although we're not sure how much an aluminium roof rack can take. Guess he'll find out.

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Can you gussett inside those plates?
I cant envisage that being an overly long lasting rigid and long lasting design?
Perhaps one of the engineers will chime in????

S

Originally Posted by roverrescue

Can you gussett inside those plates?
I cant envisage that being an overly long lasting rigid and long lasting design?
Perhaps one of the engineers will chime in????

S

Yer thats what I was saying to the owner. I did jump up and down whilst standing on it though. I'm pretty sure he wants me to do more stuff for his defendrr so I might mention it again. It is 6mm thick plate, qnd at the end of the day your only aloud 100kg on the roof.