How To Build A Custom Roof Rack With Aluminum Extrusion on a budget -Wasatch Moto Overland-

LINKS BELOW:
Virtually NO ONE knows about these specialty fasteners from Item that make building one of these roof racks EXTREMELY easy to assemble.
This video is a tutorial on how to build a roof rack or platform out of aluminum extrusion. This rack can be made for virtually any car, truck or suv that has factory bars. These are the same support bars that you will find on the Sherpa roof racks. This build is specific to a 1st gen Toyota sequoia, however this same rack can be built for virtually any vehicle. I'll be posting a video showing how easily the accessories and lights mount very soon. This can definitely be used for a roof top tent, however, I will be using it to mount my ROAM boxes, shade awning, outdoor shower, solar panel, and front led lights.
I hope you found this video informative and helpful! Please let me know if you have any questions about anything! If you found this helpful, please remember to subscribe and share! Cheers
Here are some of the products used in this video:
Automatic fasteners:
www.item24us.shop/product/003...
Installation of auto fasteners:
• The item Automatic Fas...
Automatic butt fasteners to join the two side peices:
www.item24us.shop/product/004...
Steel for brackets: amzn.to/3MAl0JZ
0:00 Removal
0:39 Laying out aluminum extrusion
1:14 Assembling the platform
6:25 Putting platform on top to make brackets
7:04 Fabricating mounting brackets
8:58 Painting the platform
9:06 Welding the brackets
Here is a list of all the goodies on my sequoia that I highly recommend:
ROAM 95L Box: amzn.to/3ME4vML
Sherpa mounting brackets: sherpaequipmentco.com/product
Aluminum for roof rack: amzn.to/3lubOef
Automatic fasteners for roof rack: www.item24us.shop/product/003
Snorkel: amzn.to/3MNYGMI
Rock Sliders: www.rocky-road.com/index2.html
9" LED lights: amzn.to/3yYthmG
Suspension, wheels & wheels:
3" spacer lift: amzn.to/3LC1DPf
Wheels: amzn.to/3MC7BRw
Tires: 285-75-17 BfGoodrich TK02 All terrains
Other items I used in my overlanding setup:
Door latch step: amzn.to/385jCQm
Curtain clips: amzn.to/3sRmI1I
Blind spot mirrors: amzn.to/3NyjgRz
Struts for platform bed storage: amzn.to/3lxBoPo
Flush mount handles for storage box: amzn.to/3G4OQ6S
Best phone mount ever: coursemotorsports.com/product...

[@hipzwhitetower7413]

About to start mine, thanks brother. New sub here.

[@wasatchmotoco]

Sweet! Thanks so much for the support! If you have any questions about anything don't hesitate to ask! I bought some plexi glass to make a fairing so I will probably have a video for that, but this thing is going to be decked out with lights and boxes and awnings so I dont think it will matter in the long run. Its a nice flat space for all your storage needs :) Please feel free to share! Cheers my friend

[@hipzwhitetower7413]

@@wasatchmotoco Thanks, most definitely will share this video. Can't wait to see you finish product, good luck.

[@wasatchmotoco]

@@hipzwhitetower7413 Thanks!

[@joshuapalmer4297]

@wasatchmotoco the link for the aluminum is single squares not double stacked for the outside frame whats the link for the double stacked or is it pretty universal, meaning I can buy any double stacked for the frame and it'll work?

[@kennethlarson5874]

What an awesome build. I'm going to do this with my 08 highlander. I'm also going to have extensions to attach at camp sites to pitch two tents on top. The mount you made for the gas and water can is awesome as well. You've done a great job with an amazing alternative idea to the more expensive routes for people that can't afford those expensive racks.

[@dillonhayes3402]

Just decided im doing this to my work van been watching a million people making campervan fitouts but this is the first roof rack one ive found keen to see your outcome

[@chrishilyer9904]

Been researching this for the last week and just came across your video. I am doing this for my trailer roof and couldn't justify the big dollar roof racks. There are a lot of really cool accessories that have come to market for big 3D printing rigs that can be adapted to extrusion bars for our purposes. Cool stuff, thanks for the video.

[@andrewr05]

Woah, those fasteners seem amazing, I'll definitely have to save up and do this 👌👌

[@scubasmith]

Thanks so much. Getting ready to start mine. Great information.

[@nbkvirus]

been watching all your videos, great stuff

[@ErnestoBorges]

Thank you so muich for showing this Im building my own platform to get above and do my photography for my travel and adventures! blessings !

[@wasatchmotoco]

Of course! Glad it was helpful for you!

[@marcolann8714]

Very nice job, I'm wondering about the noise driving it around 🤔

[@rangerdoc1029]

Nice flat roof on that Sequoia . The roof on my 4Runner has a huge arch front to rear.

[@2012ANONYMOUSA]

you made it look easy!

[@robtanner5583]

Great video 👍… my exact plan created in a video , thanks

[@ryrossssin]

I made my own using 2x1's and I will say, the window noise and vibrations is something to be aware of when DIY'ing one of these.

[@xlazyjaysx]

Nice work buddy 🤙

[@4x4xpedition]

This is awsome man!💯

[@wasatchmotoco]

Thanks man, I was surprised how easy it was to build really. Cheers

[@BroncLander]

Nice work man. Well done

[@stuartarneaud218]

Sweet bro

[@averageguylifestyle7092]

Asking for trouble mixing carbon steel brackets with aluminum. Painted or not they will start corroding. Should have used stainless for the brackets.

[@paniccity]

Very nice. Think it'll be able to heavy load?

[@kellstat]

Have you made any modifications since this video, ie. angle of the front of rack, etc...?

[@davecarter34]

great ideas here, do you know the approx weight of the rack ?

[@westleyworley1731]

Thanks for the video! Do you happen to have the dimensions by chance?

[@netguyaz]

Great video! What type of welder you used?

[@mxdaddy]

Have you had any issues with the fasteners becoming loose or wearing out from off roading or the weight of anything hanging off the rack, i.e. awning Thanks.

[@phslion]

Hows the wind resistance on this one? It seems a common complaint that some of the racks really sap high speed driving.

[@seanwhite4586]

I'm looking to build a rack for my off-road trailer. Do you know if these fasteners linked in your video will work on 10 series extruded aluminum?

[@doityourselfadventures]

Where did you get the double from

[@What-ut8vu]

Can i use sherpa bracket feet for this rack if i cant make my own?

[@henrique7846]

Awesome build, where did you get those fasteners?

[@jimilborillo]

How much would you say you spent on the aluminum extrusions as well as the fasteners? Good stuff btw!

[@IsaacRodriguez89]

I’m looking to make a roof frack for a QX80, this helps a lot. Thanks man!

[@wasatchmotoco]

Yea dude! Glad this was helpful for you! Cheers

[@wasatchmotoco]

If you have any questions feel free to ask on here

[@rustybranson4592]

I want to build a roof rack to hold a RTT. How do you know what gauge/weight of extrusion to use?

[@aramkader2068]

Anyone know what the bolts he used to connect the bars are called ?

[@stef7648]

those fasteners look sturdy af! anyone on here know if i can get em in Canada somewhere?

[@trevorkrueger1844]

Great video man! So did you do the 2040's for the sides and 2020's for the centers? What length did you cut your center pieces to? Sweet 1st Gen, can't wait to see more! Semper Fi

[@wasatchmotoco]

Hey thanks! I appreciate that. Yes that’s correct. I wasn’t sure the proper terminology for them haha. I’ve been getting a lot of questions about it. I’ll post a walk around video tomorrow with all those measurements and a closeup of the brackets. The total length from side to side was 48” so I’d venture to say the middle piece is 45”

[@trevorkrueger1844]

@@wasatchmotoco yeah the brackets are what I'm most interested in. Awesome idea going with the extruded aluminum! I've always built them out of 1" square black iron tube and this is going to be alot better I think! As far as the fasteners go, we're they sold individually or ??? I made an account with that company but can't tell how many come in a package so I'm not sure how many to order.

[@julioflores2429]

Looks like it’s been about a year, how has the paint held up?

[@Max-kn9yi]

How's the airflow noise. Has to be bad

[@josephchan7040]

Very nice. The only issue I see is that the bracket won't be able to hold the load of whatever you're holding up there. Otherwise, looks real good!

[@wasatchmotoco]

Which bracket? The breakers are really beefy so I’m sure it will do great. If you are referring to the one I had mocked up on the drivers side rear and showed briefly, I ended up not using that. I made all the brackets out of 1/8” steel plate. I’m going to be putting out a video on my ROAM box install and I’ll do an in detail walk around of the rack and brackets and everything. Cheers

[@dennismorgan9830]

The link for the 8020 is just for the crossbars. Those look like 2040-2"/4" main frame can you let me know the measurements please

[@joshuapalmer4297]

@wasatchmotoco the link for the aluminum is single squares not double stacked for the outside frame whats the link for the double stacked or is it pretty universal, meaning I can buy any double stacked for the frame and it'll work?

[@luiscastillo5025]

wow nice how much would you charge to make another one

[@206deeznutz]

Love it! Sadly I don't have the means to make the mounting brackets to attach the rack to the roof for my 04. Is that an option that you would offer? I would gladly pay for them.

[@patriotsleepercell4060]

Yes you do. Just get 1/4 inch L bracket made out of aluminium. Cut it to 3" width drill holes and voala!

[@wasatchmotoco]

Hey! I could definitely build another one of these with the single aluminum extrusion for a few hundred bucks. So materials and all you'd probably be in it 6-700. If you aren't building it yourself, it might be worth getting a Sherpa, or Gobi. But if 6-700 is going to save you some money then I could definitely build you one. I'm in Salt Lake City, Ut.

[@steve-mr8wg]

Hey brothers I live in Tampa Florida I have a 06 sequoia and I will like to buy the same running boards

[@wasatchmotoco]

@@steve-mr8wg hey man, so the lead time is pretty high right now, but call Rocky Road Outfitters and they will get you hooked up on all that info. Their number is 435-654-1149 Cheers

[@Lightgaard9440]

Did you loctite any of the fasteners? And do you know if they’ll walk out over time on aggressive trails?

[@wasatchmotoco]

They’re very easy to check, but so far none have been loose. In hind sight I probably would have lock tited all of them but that’s pretty easy to do after. Thanks for the tip.

[@ChristopherVigilgte037p]

I'm having a hard time sifting through these comments and determining which are the actual parts needed to make this rack. Any chance you'd be willing to reply with a parts list?

[@fabiangarza2640]

Great work! 👍 how the wind noise on this rack?

[@wasatchmotoco]

Not bad at all. It has a faint whistle at lower speeds that can only be heard when the windows or sunroof are down but it is extremely minimal.

[@KettlesVids]

Dang!! This is simple but sweet! How is the wind noise? I may have to copy you. :) Can't wait to see more. :)

[@wasatchmotoco]

If I didn't want anyone copying me I wouldn't have posted this for everyone to see :) I literally have found zero difference in terms of road noise. Granted I have 34" tires and they are a little noisy, but it doesnt whistle or anything which is surprising to be honest. Very simple, but very sturdy and a nice huge space for all your storage needs. If you found this video helpful, please remember to subscribe to the channel if you haven't already! Cheers

[@macho.3088]

Did you have to cut when you did 34" cuz I seen people cute around the plastic wheel well and mud flaps to put 35" tires.

[@wasatchmotoco]

@@macho.3088 Mine are just shy of 35's I did some trimming and a bit of hammering on the wheel well like where the running boards used to be in the body area there, I can do a fitment video soon on that. It has a 3" spacer lift, but I'm waiting on a 2'' body lift that will allow me to run 35's easily so when my tires wear out i'll be good to go. I'll be doing a video on the body lift install as well.

[@parkermiller1552]

Hey man. I'm a newcomer and am super interested in how you're modding this thing up. Is there anyway to still mount it to the roof if you don't have the capability to weld?

[@ampcarracing]

Go to any steel supply store or ace hardware, Home Depot,Lowe’s and buy some 1/8” or thicker angle iron. All you have to do after that is line everything up mark where you want to fasten it down and drill some holes to bolt it down.

[@ampcarracing]

Go to any steel supply store or ace hardware, Home Depot,Lowe’s and buy some 1/8” or thicker angle iron. All you have to do after that is line everything up mark where you want to fasten it down and drill some holes to bolt it down.

[@jimskatr103]

do you have a link to the double stack you use for the base?

[@wasatchmotoco]

Yes I will add that link to the description right now

[@Geo_Schiss]

Did you buy your aluminum from the Amazon links you provided? The alum in the links seems small

[@wasatchmotoco]

Yes I think that link is incorrect. I thought it was the same. My apologies

[@deangrande7207]

You should of used self etching primer , paint may flake off

[@benbecker4512]

Great video, just about to start the same project for my black vitara. I could only get silver aluminium also, has the spray lasted? I hate painting anything....

[@wasatchmotoco]

Yea it’s held up great so far!!

[@benbecker4512]

@@wasatchmotoco how many coats, what product and did you have to prep it first? Sorry for all questions lol

[@wasatchmotoco]

@@benbecker4512 no worries! I used rustoleum satin black. All of my metal came straight from a warehouse that they build stuff with extruded aluminum so it was super clean. I’d just hit it with some brake parts cleaner or alcohol and spray away! I did like 3 coats. It’s hard to get good coverage inside the t slot grooves but I got it after 3 coats I think.

[@benbecker4512]

@@wasatchmotoco cheers dude

[@J.WannaFish]

How much in parts was this build?

[@macho.3088]

How much would you charge to do this job and where your located would love for that to be on my sequoia. Just don't want a bar to block my sunroof opening.

[@wasatchmotoco]

If you found this video helpful please make sure and subscribe to the channel! Cheers

[@macho.3088]

@@wasatchmotoco I already subscribe.

[@ferretface8782]

I need a roof platform strong enough for two adults in chairs. Is this strong enough?

[@ethanrandall3005]

Short answer: Yes. Long answer: This guy listed 2020 as what he used for this build (or the company who made the posting on Amazon shuffled their products between then and now, as shitty Chinese companies tend to do). You'd want to use 1515, and as far as I can tell, this guy's build is either 1010 or 1515 (depending on the size of his hands). Make sure you have an actual engineer give you feedback on your plans before you commit to the build. Might save you a lot of hassle and maybe even a whole lot of epidermis. The failure point for most builds with modular extrusions (which a LOT of industrial machinery is built out of) are not the beams themselves! It's the connections. Use proper connections! Flat brackets. Gussets. The nifty little self-thread things this guy used? Probably good enough to hold a light bar on a bumpy road, but even then, I wouldn't trust it given the lack of tortional support. They likely won't move laterally... until they twist since the only connection point is a two bolts **on the same axis**... which will also turn the beam into a worm gear and try to pry apart the beams and/or strip/shred the threads or beams themselves. Pretty much the worst possible mounting solution you could use other than duct tape. If you do use these inserts for whatever reason (which also permanently damages your beams (and their structural integrity by a small amount)), at least install additional cross-beams in a way that prevents any of them from rotating. That should fix the shortcomings of these thread things. However, if you need to install additional beams to support these beams, it'll be cheaper, better, and more compact to just use proper mounting solutions between the existing beams. Only counting the EXTERNAL FASTENERS for size 15 extrusions, 8020 sells 234 unique parts, and not one of them is the stupid thread thing in this video. If you can think of it (and it's applicable to more than one use case), they've got it.

[@bigfootgoesboom]

Hey man the link for the extrusion seems messed up if you want to fix it.

[@wasatchmotoco]

Thanks! Got that fixed up. If you found this video informative please subscribe to the channel for more overlanding/camping/ videos! Cheers my friend

[@deangrande7207]

I made mine out of Unistrut , boy did I get a loud howling noise

[@nathancharbonneau-4631]

I think if you painted it black it would look better.

[@qcmariculteur]

The link for the aluminium extrusion is no good. It is not the right size. I assume you used 1.5in X 1.5in for bars and 1.5in X 3in for the sides. Am i right ?

[@wasatchmotoco]

Yes but I’m my video I stated that you can build this whole rack with single 1.5” bars. I have a connection with a friend that uses this for work and he happened to have the double so I used that for perimeter. If I had to do it over again I think I’d build it with single as it would be lighters and in my opinion equally as strong.

[@qcmariculteur]

@@wasatchmotoco Perfect It is what i wanted to know. I ordered the item fasteners and i wanted to be sure to use te right size of aluminium extrusion. Thank you for the reply !! .

[@bigfootgoesboom]

@@qcmariculteur how many fasteners come in a set? I can't find it anywhere on their site

[@qcmariculteur]

@@bigfootgoesboom I don't know. I bought mine used from an Ebay seller. I am from Quebec Canada and could not find a retailer for those fasteners. U.S. site that i found that sell them new do not ship in Canada.

[@stef7648]

@@qcmariculteur where did you end up ordering your stuff from? From what I can judge here he is using 8040 for the perimeter and 4040 for the cross sections, I am also in Canada, but pricing those "profile 8" sections and fasteners is super$$$!

[@patriotsleepercell4060]

Why didnt you just get black instead of silver and had to painted black? hahaha It probably works well but looks terrible! Just my opinion.

[@koalafan1576]

That’s what I was thinking, they make black extrusion.