[Jeepersjoey]

Hello!

Since I had a trip (that was cancelled!) that required me to haul enough stuff for three people, 12 days, I needed a way to increase my cargo box.

I bought the first for $70 and then the second for $40. Cheap!

I am a HUGE fan of 8020 Extruded Aluminum so I made it from the Series 10 (it is 1" square).








This one shows the extra 3" pieces of 8020 that I added right where the boxes attach. This makes the mounting 3" in width instead of 1" in width.



Look at the awesome channel that I made where the box cannot slide!













Here is the final product. Unfortunately, at 55mph it whistles pretty bad. 8020 makes covers that would fill all the extruded shapes that are causing the noise. If I ever need to use this, I will probably add the 8020 covers.


Also, the 8020 bars I added are 8 ft in length. I could definitely reduce the length of them and push the two boxes closer together.

The boot opens without hitting either box.

One unfortunate fact is that both boxes open on the same side. So, you have to reach over box #1 to open box #2.

Enjoy!
Paul

[pierreye]

Wouldn't it be illegal for the bar to be longer than the width of the car?

[Speedbird1]

Wow, looks like a great project and an interesting mounting solution. The only part I can see that 'may' be a weak point in your design are the 12 uprights of the angle brackets. In the orientation they are in, they will be subject to all the fore and aft load that is exerted on them when accelerating and braking.

I would keep a close eye on them to ensure there are no signs of metal fatigue. Obviously this observation is purely based on what can be seen in your pictures and it doesn't look like it would be a disaster if they did bend, but probably worth thinking about.

[Jeepersjoey]

Very good point. The gusset on the l-brackets provides strength in the opposite direction that I mounted them. As if the wind would be coming from the back of the car.

I mounted them this way because I wanted the weight directly inline with the bars rather than offset.

If I end up using them, I am going to look at reversing them.

Interestingly, I removed the 8020 bars and had them on the ground. I don't remember stepping on it, but one of the plates and two l-brackets is bent. Not as strong as I was expecting.

Paul

Originally Posted by Speedbird1

Wow, looks like a great project and an interesting mounting solution. The only part I can see that 'may' be a weak point in your design are the 12 uprights of the angle brackets. In the orientation they are in, they will be subject to all the fore and aft load that is exerted on them when accelerating and braking.

I would keep a close eye on them to ensure there are no signs of metal fatigue. Obviously this observation is purely based on what can be seen in your pictures and it doesn't look like it would be a disaster if they did bend, but probably worth thinking about.

[Tricky401]

Great project however it would do my ocd in that they are slightly different boxes. Also can they not be pushed closer together?

I would also be concnered about the loaded weight once both are full. I’m sure there’s a limit the rack can safely carry