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

 

I was admiring that in your initial post, one stout and well thought out rack, very nice indeed!

 

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?

 

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

 

Heck with plastic.....bring on the aluminum! Looks very well built

 

that is killer!... and looks great..... I want one too!..
.

 

Very nice work!!!

 

 

That is a very nice rack. Good job.

 

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