How To Build A DIY Roof Rack For Your Vehicle

A nice, sturdy DIY roof rack can add a ton of cargo space to your vehicle. It only requires a few basic hand tools and materials you can easily get at your local hardware store.

RELATED: 25 Smart DIY Hidden Storage Ideas For Every Corner Of Your Home

How to Build A DIY Roof Rack and Add Even More Storage

What You Need:

• 2 in. x 0.25 in. aluminum tubes (for the sides)
• 3 in. x 3 in. x 0.25 in. aluminum angle, cut into 3 in. sections (for the feet)
• 1 in. x 2 in. extruded aluminum (for the crossbars)
• Aluminum spacers (for the roof mount holes)
• Black truck Bedliner spray
• Threaded rubber bumpers

2" Aluminum Square Tube 1/4" Wall x 36" Long 6061-T6 Mill Finish

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Industrial Metal Sales - 6061 T6511 Extruded Aluminum Angle 3" x 4" x 12"-Long x 1/4" Thick

• Unpolished,Mill Finish,Extruded,T6511 Temper

$35.93

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8020, 1020, 10 Series 1 Inch x 2 Inch T-Slotted Aluminum Extrusion DIY Extruded Linear Slot Bar Rail 80/20 (Clear Anodize, 36" Long)

• 10 Series 8020 Modular Extrusion with six open t-slots to accommodate 1 inch x 1 inch based joining plates, brackets, and accessories.
• High strength 6063-T6 aluminum with an anodized finish offers great flexibility and strength for your linear rail, track saw guide, linear motion guide, and many more applications.
• With superior quality control, you know you are getting the best t slot aluminum extrusions when you order 8020 aluminum extrusion. Deburred ends, clean cuts, and tight cut tolerances are guaranteed.
• 80/20 aluminum extrusion profile is a good linear motion material and allows adjustable placement of all components.
• Applications include automation equipment, professional 3D printer, workbenches, lasers, stands, furniture, machinery, fitness equipment, precision printers, guarding, woodworking and t tracks.

$26.27

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Small Parts 310410RSA Round Spacer, Aluminum, Plain Finish, #10 Screw Size, 5/16" OD, 0.192" ID, 1/4" Length (Pack of 10)

• Length: 1/4"
• Shape: Round
• Od: 5/16"
• Id: 0.192"

$4.73

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Custom Coat Sprayable Truck Bedliner - Extra Large 14.4 Ounce Spray Can - Black - A Great Aerosol Truck Bed Liner for Touch-Up or Complete Truck Beds

• Custom Coat Aersol Sprayable Truck Bed Liner - Extra Large 14.4 ounce Spray Can - provides a black matte, textured, non-skid finish for Truck Beds, Tailgates, Bed Rails and Running Boards. Easy to use aerosol spray can.
• Custom Coat Aerosol Bedliner Gives faded bed liners new life, repairs Spray-in Bed Liners, durable and abrasion resistant, textured non-skid finish
• Protects against corrosion and abrasion, withstands impacts, provides improved traction, and resists water
• Flat fan high atomization nozzle offers a large fan pattern and excellent coverage
• Versatile: Can be easily applied to many other surfaces such as concrete, plastic, rubber, metal, wood or fiberglass to achieve a Textured satin black finish

$21.99

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Set of 4 Adjustable Rubber Bumper Feet, Levelers, 8-32 Thread Size

• 𝐏𝐑𝐄𝐌𝐈𝐔𝐌 𝐑𝐔𝐁𝐁𝐄𝐑 𝐌𝐀𝐓𝐄𝐑𝐈𝐀𝐋: These adjustable bumper feet are crafted from high-quality rubber, known for its durability and resistance to wear and tear. The robust rubber construction ensures long-lasting performance and protection for your equipment or furniture.
• 𝐕𝐄𝐑𝐒𝐀𝐓𝐈𝐋𝐄 𝐋𝐄𝐕𝐄𝐋𝐈𝐍𝐆 𝐒𝐎𝐋𝐔𝐓𝐈𝐎𝐍: Designed with 8-32 thread size, these bumper feet are suitable for a wide range of applications. Whether you're leveling machinery, electronics, cabinets, or furniture, these feet provide a stable and adjustable solution.
• 𝐏𝐑𝐄𝐂𝐈𝐒𝐄 𝐇𝐄𝐈𝐆𝐇𝐓 𝐀𝐃𝐉𝐔𝐒𝐓𝐌𝐄𝐍𝐓: With a stud length of 0.341 inches and a foot height of 0.480 inches, these feet allow for precise height adjustments to achieve the desired level. This feature is particularly valuable when working with uneven surfaces.
• 𝐒𝐄𝐂𝐔𝐑𝐄 𝐀𝐍𝐃 𝐒𝐓𝐀𝐁𝐋𝐄 𝐒𝐔𝐏𝐏𝐎𝐑𝐓: The 0.684-inch outer diameter (OD) of the rubber foot ensures a stable and secure base, preventing slipping or sliding. These feet provide reliable support, reducing the risk of damage to your equipment or flooring.
• 𝐂𝐎𝐌𝐏𝐀𝐂𝐓 𝐀𝐍𝐃 𝐅𝐔𝐍𝐂𝐓𝐈𝐎𝐍𝐀𝐋: With an overall height of 0.821 inches, measured from the base of the rubber foot to the top of the stud, these bumper feet offer a compact yet effective solution for leveling and protecting your valuable assets. The set of four ensures you have enough for your needs.

$7.99

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Step 1: Get Some Measurements

Before getting started on your roof rack, you will have to take a few critical measurements. Here are the ones you need to take note of:

• Distance between the existing roof rack mounts (the two front mounts and the two rear mounts)
• Angle of the top of the windshield
• Length from the windshield to the back of the vehicle with the liftgate opened
• Dimensions of your sunroof (if you have one)

Step 2: Plan Out Your Design

Once you’ve taken your measurements, plot out your roof rack’s design. When planning out where to put your crossbars, leave a gap for your sunroof (if your vehicle has one) and allow for a bit of allowance on the sides.

Step 3: Tap the Extruded Aluminum

If you haven’t already purchased the extruded aluminum pre-tapped, start tapping them on either side. You will then have some holes where you can screw the bolts on the sides of the roof rack.

What is Tapping? Tapping is the process of drilling a hole in such a way that you can thread a screw or bolt inside later on.

Step 4: Drill the Side Pieces

Drill some holes on both side pieces corresponding to where your crossbars should be. Since the side pieces are 2 in. tall and the crossbars are 1 in. tall, drill four holes for each crossbar location so you can have the option to mount them on top (for a rooftop tent) or at the bottom (for general storage)

RELATED: 11 Awesome Garage Storage Ideas To Keep Your Tools Organized

Step 5: Cut the Sides to Length and Test the Pieces Together

Cut the side aluminum pieces to the desired length. Once everything’s drilled down, ask someone to help you assemble the side pieces of your DIY roof rack to your vehicle’s roof. Make sure your rack’s at the center and use a few wood blocks to set it at the right height

Step 6: Prepare the Roof Rack Feet

Next, clamp your aluminum angle to your rack, drill holes to the side pieces, and use a marker to mark where the roof mount feet holes are located. Drill some holes corresponding to those locations after.

Step 7: Paint and Assemble it All Together

Now that you finished all the drilling, it’s time to paint all the pieces with some bedliner spray paint. Let it dry.

Once the paint has dried, bolt in the pieces to your vehicle and check how it comes together.

Step 8: Create Some Rubber Bumpers for Support

To add a bit of extra support, add a couple of rubber bumpers near the front of your roof rack. This prevents your rack from swaying from side-to-side when moving off.

Here’s how to create the bumpers:

• Place a T-nut stud at the bottom of the first extruded aluminum in front.
• Screw the spacer down tightly onto it.
• Add a jam nut to your rubber bumper
• Adjust the height until there’s a bit of pressure between the rack and your vehicle’s roof

This is how it should look like and how this roof rack is made:

The sky’s the limit once you put your DIY roof rack together. We hope you enjoyed this simple tutorial and stay tuned for more.

Have you already put together a roof rack for your car? Let us know in the comments section below!

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