The process always starts with what we want mounted on the roof rack and reverse engineering it from there. For instance, we were using the Diode Dynamic lighting and wanted it to be configured so it is flush with the top of the roof rack. Also wanted room for a side light so that gave us the base height we needed to build off of the roof of the truck.
I cut some pieces of masonite as you can see in the above picture, this is what I typically use to pre-fit everything. From there, I will completely assemble the rack using half-inch HDPE ultimately, I wanted to do it in powder coated aluminum, but we were needed to get it done immediately.
an important part of the process is how we 3-D scanned the truck to allow us to make the wind fairing and other adjoining parts. Check out this one minute video which shows our process.
As you can see in the picture below, the wind fairing fits perfectly, although it is still done in HDPE plastic, we have created the file and are ready to make the final roof rack out of quarter inch aluminum, with a powder coat finish
Although we cut the final product out of aluminum on our CNC machine, we weren’t totally happy with the outcome so we used a local guy to cut it on his water jet and also cut in our logo which we could not do.
At this time, the reassembly was quite easy, however, we added in the solar panel, which feeds the independent electrical system with the lithium ion battery. The solar panel was mounted flush with the 8020 aluminum for that seamless professional look.
Check out these completed photos!
Couldn’t be happier with how this turned out, if you are interested in something similar for your vehicle, please reach out to us, especially if you were in the Connecticut area. We do custom vehicle up fitting whether it’s a van for work or a truck for Overlanding. Please keep us in mind for your next project!
You can find us on our website ModMyRig.com or email me directly at brian@modmyrig.com
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