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Custom Aluminum Roof Rack

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Old 10-26-2011, 08:10 AM
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Join Date: 10-04-2011
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Custom Aluminum Roof Rack
Hello All...

The most extensive modification I've made to my 2010 HHR Panel, has been the addition of a full length, custom bent & fab'ed, oval tube aluminum roof rack. This vehicle was purchased, new in February of 2011, and immediately had the interior headliner removed to allow access to the roof structure for a 'thru-bolted' roof rack design. Note: The roof rack is attached to the Roof Bow Structure, thru-bolted & shimmed to prevent roof panel deflection and then sealed with 3M 5200 Marine Adhesive to prevent water leaks. It's totally stout & structual to the car!

The primary vison for the purchase of this vehicle was to be a cool looking, unique, canoe/kayak transporter while (hopefully) getting decent gas mileage... It's getting closer to the mission all the time.

Here's some pictures of the fab & installation of the roof rack...

Mounting Surface & Thru Bolt Stud:


Beautiful Welds & Tapped Hole for mounting stud:


Rough Installation to Roof Top:


Tweaking & Fitting before Powdercoating:


After Powdercoating & Final Installation:


Ready to Roll:


Comments &/or questions? Lay it on me...

KEENO
Last edited by KanoeKeeno; 10-26-2011 at 08:50 AM.
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Old 10-26-2011, 08:14 AM
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I was admiring that in your initial post, one stout and well thought out rack, very nice indeed!
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Old 10-26-2011, 08:51 AM
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Great rack, I haul kayaks alot also, but have to use a trailer with my other car. Haven't set up the HHR yet.

You drive a panel but have 3 boats on the roof, Where does the third person ride?
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Old 10-26-2011, 09:25 AM
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Thanks for the replies & comments...

843de: Thanks for the compliments!

11BlueJ: I guess I had a spare that day to paddle with friends, no room for another person unless you can fit in the storage compartments.

KEENO
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Old 10-26-2011, 10:58 AM
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Heck with plastic.....bring on the aluminum! Looks very well built
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Old 10-26-2011, 11:10 AM
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that is killer!... and looks great..... I want one too!..
.
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Old 10-26-2011, 11:43 AM
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Very nice work!!!
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Old 10-26-2011, 12:09 PM
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Originally Posted by Alexwsilver2010
that is killer!... and looks great..... I want one too!..
.
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Old 10-26-2011, 01:34 PM
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That is a very nice rack. Good job.
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Old 10-26-2011, 01:51 PM
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I noticed the lack of "cross bars" on the rack. Was this done purposely due to the rack being a bolt through design? Very nice work BTW and welcome to the forum!

Later
Allex
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