Smallest yet durable enough tubing for roof rack?

[Demonoid369]

I know some use poop pipe to build theirs but we also all know how heavy these roof baskets can get so I'm kinda wanting to research what type of iron/mild steel/etc..(not aluminum) size tubing can I use that will be the lightest but durable enough to hold gear? It's never going hold a tire but a jack and other misc stuff it will. Just trying to get a rough idea, it will be a full length rack if that helps

 

[bluejeepkid]

I used .065 for thickness on mine, various tubing sizes tho

 

[Phil]

1x1x0.065 should be swell. Probably even step the interior cross pieces down to 3/4x3/4x0.065. Really, what will you have up there? Hi-lift on the edge of the rack and a couple sleeping bags and a tent?

 

[Demonoid369]

Ya it'll have a hi-lift, sleeping bags, tents, other camping stuff, etc... I just want to keep the weight as light as possible to avoid top heaviness since I plan to build my jeep to be an expedition jeep so light as possible to not weight it down so much.

 

[offroadordnance]

One day you'll need to put something heavy on your rack and the 20 pounds you saved won't matter. But I'm biased http://www.cherokeeforum.com/f58/poop-pipe-roof-rack-170629/

 

[xcm]

Build smart, and the added strength from structure will more then make up for a little less crush resistance.

Overbuilding is wrong and lazy.

 

[xjtrailrider]

I used 1"x1"x3/16" square tubing and some black pipe for my roof sliders and it only weighs in at 55#. I don't have a big basket up there but I do have a Yakima Basket Case and it only weighs 12#. Works well for holding a chainsaw and some camping gear etc.

 

[jmaxj]

I use 1" .060 wall HREW round tube. So far the racks have held up great to everything. Plus they're pretty light weight and strong.

 

[old_man]

I used 1" x .065 steel for the bottom perimeter, and .75" x .065 for the top rail. The cross members were 1.25" x .75" rectangular for the cross pieces. I used expanded mesh for the floor.

The biggest design issue becomes the mounting.