ok, I apologize for the only got a couple of shots of it... but here's the
deal....

http://www.burntorangedesign.com/xterra/rack3.jpg

We were either pulling an all nighter to get it done, even then, we were not
sure if it'd be done, or we get it all aligned, measured, marked and such,
and Rich can finish it up, 2 weeks I will have it again (he's taking a
vacation in Hawaii...) but man, it's soooo close.

First off, it's huge! 7.5 ft long, I could comfortable sleep in it. Think
we miscalculated where the roof bend is, we were off by a good 8-10 inches.
It would've been nice to have that extra bit of deep space, but I don't
care, looks like 5 jerry cans can fit in it up front, laying lengthwise (on
their side) maybe 6, I didn't have 6 on me. the body mounts are beautiful.
exactly match the shape of the factory roof rack mounts, I just need to get
some good padding material. any suggestions? should be expandable, from
1/16-1/4inch thick. I picked the rack up, it's not aluminum, but it's not
too heavy. I am guessing 45-50 pounds, before we put on the expanded metal
bases. It's really big, it hangs over the windscreen, fine with me, that's
wasted space in my book. We are welding a bar accross the front, 5" behind
the front of the rack, to protect the lights from the jerry cans. We unbent
my hilift on one of his presses, and he's fashioning a hi lift mount on the
side. He's got one so I didn't have to lend him mine.

the expanded base screens are going to get powdercoated, that's up to me, I
just need to find an outfit that'll do them. They will be removable, and
should be the perfect base for mounting lots of items like waterproof bags
and such for the long trip.

the welds will clean up with some scotchbrite, and it'll remain unpainted.
it's pretty damn cool.

ok, ok, photos...

http://www.burntorangedesign.com/xterra/rack2.jpg

http://www.burntorangedesign.com/xterra/rack4.jpg

again, I apologize for the lack of shots, but I was expecting to get shots
of it complete, at 8:45 we decided it probably wouldn't get done tonight. 2
more weeks....

I hope you take this in the constructive way it is intended, but didn't you just create the Calmini rack?

http://www.purenissan.com/roofrack-big.jpg

mine's made out of beefy 1" stainless. it's also longer, and yes, it looks the same to a point. I guess the key word is, this is my own design. I came up with the idea before I saw Calmini was building one. and I guess I could've bought theirs, but this one is free, and it's getting groovy custom appointments to boot.

I like their rack. it's nice.


this would probably fix the weird angle. think it'd be easy for them to do it.

http://www.burntorangedesign.com/xterra/rack1.jpg

__________________
The guy with the ugly naked yellow X

And you didn't like my aluminum "chrome looking" bullbar??? :) It definately looks to be more functional than the factory rack.


Originally posted by Matt Peckham
I just need to get
some good padding material. any suggestions?


Maybe some thick rubber from a pickup truck bed liner or mud flap.

http://www.burntorangedesign.com/xterra/rack1.jpg http://www.burntorangedesign.com/xterra/rack4.jpg

Is it just me, or did the size/shape of the front part change between these two pic's (in addition to the position on the X)? It looks like there's another vertical piece added in the second picture, and that the front section is longer than the first. I love the rack. Personally, I'd powdercoat it matte black, but that's just preference. I hope you put more crossbars on the "floor" of the rack than Calimi did, there's doesn't offer much protection to the roof. What type of welding did you use for it (stick/MIG/TIG/etc...)? Also, how much did the raw material run you? Also, what is the wall thickness of the tubing? I'm looking to do one of these myself this fall, and its easier if you work out the fine details for me. :) I think the truck mud flap idea for padding is a great one. I was wondering about that aspect myself.

I had made a mockup of what it would look like if the piece were moved back a bit and the vertical bar added, I like the effect. I will talk with the fabricator today to see what he can do about fixing that. I can ask what type of stock he used, but it's stainless, somewhat thin walled 1" square hollow tube stock.

if we move that angled part back about 8 inches, it should line up perfect.

There aren't that many crossbars on the floor, but we are also putting down expanded metal that will bolt to the sides, and allow for plenty of strength, and they'll be removable if need be.