DIY Roof Rack Part 1 - Unistrut Mounting Rails for Under £50! | Sprinter/Crafter Van Conversion

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We made our own DIY Custom Roof Rack Mounting Rails for under £50! Instead of paying hundreds (or even thousands) for a roof rack, we instead decided to build our own. The first stage is to build a mounting rail for our roof rack to sit on, and unistrut was the perfect material to use as it is cheap, has lots of fittings, and is easy to work with (and coincidentally, is a perfect size).
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#diyroofrack #unistrutroofrack #vanconversion

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Опубликовано:

21 авг 2020

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Комментарии : 135

@jamiebarrette3630 3 года назад

Nice job! Only thing is your lock washer belongs on the nut end not bolt, its pointless on bolt end.

@whatyousaidbud 2 года назад

It's also pointless painting galvanised unistrut for rust protection.

@ThisEffingGuy 2 месяца назад

Lock washers work fine on the bolt side. They work by exerting force along the axis of the bolt, keeping the entire assembly under extra compression. Makes no difference whether they are touching the nut.

@crippyandkaatje 2 года назад

So grateful, after endless search to come across detailed explanation. Going to apply to my minivan! Thanks, best wishes.

@FreedomStrider 2 года назад

Great to hear, hope it goes well 😎

@Albeare 3 года назад

Hi Folks, great video thanks for sharing. Happy travels.

@FreedomStrider 3 года назад

Thanks 🙂👍

@tine8849 3 года назад

All you Sprinter/Crafter people love your Unistrut. Probably ruined the industry for roof rails. This is one of those jobs I want to do early on in the build. I want all the externals holes done and leak tested before I start filling the van with stuff. I don't know if that order of works entirely makes sense but it seems sorta logical.

@FreedomStrider 3 года назад

That's our logic as well, get all the holes drilled and everything sealed up, then once that is confirmed watertight, we can proceed with covering it up. Roof rails are usually way overpriced, and we needed a more universal fixing method to be functional with the rails we got, as we're customizing a lot of things. Logically, cut the holes first, waterproof it, then you do the inside, but don't sweat too much if things go out of order at points. 🙂👍

@Fit4Expedition 3 года назад

I need to do this on my box van that I'm converting. Thanks for the tips.

@FreedomStrider 3 года назад

You're welcome, they're a great easy option 👍

@SallyAndEd 3 года назад

Hey guys! This is super interesting. We've been planning to do something similar in the next few weeks. We've been looking for roof rack suppliers for Sprinters in Aus, but for a LWB we've been quoted 3 or 4 thousand. A unistrut rack might be the way to go for us. Can't wait for part 2 :D

@FreedomStrider 3 года назад

If you're willing to DIY it a little, Unistrut is the way to go! Looks like you can actually buy Unistrut in Auz as well: au.rs-online.com/web/b/unistrut/ Once you have these main mounting rails down, you can use unistrut channel nuts to just bolt nearly anything ontop - we're just figuring out how to build our roof deck lightweight, because regular wood decking would weigh around 100-150kg

@FreedomStrider 2 года назад

If you were still wondering about part 2, we (finally) released it :D --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@erniepease 3 года назад

I like the idea. I am an airline mechanic. I noticed one area for a suggestion. You should place the split washer against the nut instead of the bolt head.

@FreedomStrider 3 года назад

We did wonder where is the best place for the split washer - most people's advice differed from each other. 😀 We have more bolts to do, so we could update our method. Why would you say against the nut is better?

@erniepease 3 года назад

@@FreedomStrider THe moving part needs the most friction so that it won't back off. the bolt has most of the friction already. You don't want the nut to back off and come loose. Most manuals will tell you to place it against the nut. There are a few exceptions. You can forego a split washer if you use a "nyloc" nut. That is one with a nylon ring pressed into one side of the nut

@FreedomStrider 3 года назад

Cheers!

@robertlee3734 3 года назад

well done you two great way to do it

@FreedomStrider 3 года назад

Thanks! 😊

@dhinakaransenthil6756 3 года назад

I'm gonna try this on our Isuzu DMax , thanks for your good work 👍

@FreedomStrider 3 года назад

You're welcome ☺️👍

@anthonysuperina3056 3 года назад

Nice work , Heads up for all , Channel comes in Alloy and in 6metre lengths with no holes , no need to line up with Van existing holes just mark from below and drill

@FreedomStrider 3 года назад

👍🙂

@russ3580 3 года назад

Good show and well done!

@FreedomStrider 3 года назад

Cheers 👍😎

@FnAVanLife 3 года назад

you guys are killing it! keep working hard. We love watching the build series!

@FreedomStrider 3 года назад

Thanks! 😀 - we are making headway... soon to start building the kitchen

@Pejman07 Год назад

all good except lock washer was placed in the wrong spot, should be inside the van behind every nut to prevent nut from opening under vibration

@FreedomStrider Год назад

Yes we've been told this a few times, we did use threadlocker as well but it wasn't shown 👌👍

@theoteam4641 3 года назад

Wow it looks great, keep up the good work. I can’t wait to see the tilting solar panels and roof deck :-)

@FreedomStrider 3 года назад

Thanks! We are still working on it - trying to determine whether we have enough room for actuators and what we need to do for wind safety. But it coming - soon-ish 😂

@theoteam4641 3 года назад

Freedom Strider ah that’s fine, as long as you have over 25 degrees or so angle on the actuators then you can have very little clearance and it would work. If you have about 10CM height under your solar panels, you can put wind deflectors in front of them and that would be fine ☺️.

@590studio Год назад

In order to get paint to adhere properly to zinc or other plated strut you'll need to first apply Zinc Chromate primer. In order to remove those roof hole plugs easily and without risk of scratching the paint, use a plastic automotive trim tool. Assortment packs are available at auto parts stores cheaply.

@FreedomStrider Год назад

Good tip, yeah we should have used a proper primer but 3 years later its still good and not rusting!

@bertsbug 3 года назад

6:08-6:11 awesome show... My new screen saver ....... Just kidding 😂

@FreedomStrider 3 года назад

So glad to find such passion about Unistrut 😂

@mikeadams5111 3 года назад

Good video--thanks

@FreedomStrider 3 года назад

Glad you enjoyed it. 🙂👍

@johnbarclay88 3 года назад

Great. First vid I've seen on this subject. Question: did you need to remove all the plugs given that not all the holes aligned with the unistrut? Also, are you tempted to shorten the bolts before use so they don't stick so far into the van?

@FreedomStrider 3 года назад

We didn't have to remove them all (technically) but we wanted as many securing point as possible (as there aren't that many actually). So when they didn't aling we just extended the holes, and we would do the same next time. We are not tempted to shorten the bolts as our insulation is covering perfectly. But you can use shorter bolts - we used 40mm and the minimum we could get away with is probably 25mm -ish 😀

@MohsenTabrizi 3 года назад

Hi, good job, I ‘m going to cut up the airline track from inside the camper and install it on the top, didn’t yours come with airline tracks? New for 8 meters costs 240€! I’m going to do it tomorrow , thanks for the tips. Keep up the good job. Cheers

@FreedomStrider 3 года назад

Good idea! Ours did not come with anything but 5.5mm ply, so we had to get creative 🎉

@GroomLake-Gremlin 11 месяцев назад

I'm getting ready to start this (unistrut) project ... finally. Just thought I'd check-in with you two and see how it has been holding up over the past 2 (3?) years ?? Anything you'd do differently now in retrospect? I honestly have no idea if you'll see this comment, or have time to reply ... but I thought I'd try. ❤Love your content, and will continue to follow regardless. 😊

@FreedomStrider 11 месяцев назад

Hey hey! It's held up well, no rust or leaks! Only 1 thing we'd do different, and that's install rivnuts in the roof holes, rather than putting bolts and nuts in. Mostly incase we need to remove the unustrut, it can all be done from the top, rather than having to undo the ceiling from the inside to reveal the nuts. So far, haven't needed to do that though :)

@nasty.nick.p 3 года назад

You should use rivnuts to bolt the unistrut on as when you have finished your conversion if you need to remove them for any reason you can't as the nuts will be hidden behind your insulation and panneling

@FreedomStrider 3 года назад

You know - that exact thought occurred to us about half an hour after finishing the job 😂 - hindsight is a 💥😱... it's okay, we'll deal if it ever comes to it... next conversion we'll remember.

@tine8849 3 года назад

I didn't quite get what you meant as everything is hidden behind insulation anyway but I take it you mean you can't easily unscrew them because you'll need to stop the nut spinning underneath. That's a damn good tip, If I've visualised that correctly.

@FreedomStrider 3 года назад

I think you visualized correctly - Rivnuts are a much more modular and clean route than using the nuts. Just wish it had occurred to us before committing to what we did. I suppose if we ever need to remove the rails we can upgrade the holes. And the ceiling cladding will be removable so we'' just need to cut through the PIR board. 👍

@nasty.nick.p 3 года назад

@@FreedomStrider it makes it easier as well if you do get a leak

@jessestrum 3 года назад

hi guys lovely job ,just one thought if you open all the holes, and fitted rivet nuts, these can be fitted without the fancy gun. so if you had to remove struts you would not need access from below. thumbs up john

@FreedomStrider 3 года назад

Yes we did think about rivnuts, I think if we were to do it again we would go with rivnuts 👍😊

@deltron708 3 года назад

Good work guys. I just wanted to check as it's not shown on your video: does the 21mm height of the struts clear the slight curvature of the roof? In other words, when you lay another piece of strut width ways resting on top of the long length struts, does it completely clear the roof? Hope that makes sense. Many thanks, D

@FreedomStrider 3 года назад

Right, if we are visualizing your question correctly, a strut resting width ways on top of the 21mm tall strut (running along) will clear the roof - but only just. - I think its about a centimetre clearance. Personally, we plan on putting rubber feet on anything that low - just so metal doesn't rub metal if the strut sags. 👍🙂

@dbucka 2 года назад

Great info! If you had access to those hole plugs from inside the van, it seems easier to squeeze the stem of the plug and push it out. Otherwise there are panel removal tools for such jobs that are much easier and don’t scratch!

@FreedomStrider 2 года назад

You might be able to sqeeze them from below, though the cap sealant is pretty strong, so you will have to use a heatgun from above.

@dbucka 2 года назад

@@FreedomStrider good point. Top notch work!

@lollyjenkins 3 года назад

Looks great guys! Might be an idea to stick the bolts up from below so if you ever need to remove the rails you won’t lose the nuts somewhere in the roof space and easy to screw back in without any faf!

@FreedomStrider 3 года назад

Took us a while to visualize what you meant 😂... but yes, that is a good idea - just need to align the nuts carefully. 👍

@lawrencedavidson6195 2 месяца назад

Nice work, greetings from Jamaica.

@FreedomStrider 2 месяца назад

Thanks 😊 👋

@georgewalsh9687 2 года назад

I’ve just done the dry fit for this and I’m hearing an arcing sound within the van. Will the tape stop this or do the struts need grounding to the van?

@FreedomStrider 2 года назад

Hum, interesting, we never noticed any arcing with ours. By the sounds of it, you have some exposed 🙂👍(unpainted) metal making contact with the unistrut, so I would say the butyl tape or a neoprene strip would insulate it.

@futbol1972 3 года назад

Can I use an impact drill to drill holes on side of unistrut rail or should I use just a drill or something else? I am using it for two punching bags with trolleys so I can move them out of the way when not using them..however I wanna drill holes on the side of rails so I can insert bolts to stop bag from sliding when punching it

@FreedomStrider 3 года назад

You might be able to, although Unistrut is pretty tough stuff so using a powerful drill driver would probably be best. There's many different types of drills and we sometimes get confused which is which, but I believe the impact drill doesn't apply as much pushing force into the material, it's main job is applying rotational force, whilst a drill driver does both to drill an effective hole.

@jones1068 3 года назад

Nice vid.

@FreedomStrider 3 года назад

Thanks! 🙂👍

@ericvlog 2 года назад

Nice 👍

@FreedomStrider 2 года назад

Cheers!

@tobiasmenke4890 2 месяца назад

What blade do you use to cut the unistrut with the mitre saw?

@FreedomStrider Месяц назад

It was just a standard metal amd wood blade, nothing special and ours is pretty blunt 🤣

@paulinetaylor1491 3 года назад

did you raise your unistrut up to take the roof height into account? The roof if higher in the middle? Cheers

@FreedomStrider 3 года назад

We checked beforehand, with the feet for our solar rig and roof rack crossbeams, they should just about fit the width of the van, over the higher middle. We went with the shallow Unistrut beams because we liked the look of them, but you can get 41x41 which will give you a little more clearance 👍

@goga275bwb 2 года назад

Could you tell me what kind of tape you use . Please write the name of this tape.is this warer resistible tape.

@FreedomStrider 2 года назад

The grey tape is called butyl tape - it is water-resistant but not waterproof and over time it may give to weathering. Its main use in our case is to act as a shock absorber and the water part for us is the sealant we used. An alternative to butyl tape is closed-cell neoprene strip (this will actually be waterproof (though use sealant just in case - especially around the bolts)

@chriskelly8172 3 года назад

Is part 2 of this video available for viewing? would love to check out the rest of the roof rack install. Great video and thanks for sharing

@FreedomStrider 3 года назад

Not yet, this is the most important part since you can literally mount anything to the unistrut once that is on the roof, but we are working on it soon 👌👍

@FreedomStrider 2 года назад

If you were still wondering about part 2, we (finally) released it :D --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@MrMatthewKerr 3 года назад

Hi. Please can i asked what was your procedure for preparing the Galvanized metal? You appear to be scraping it off with a credit card and also etching the surface with sandpaper. I was thinking of simply using wash primer. But maybe that's not enough. thanks a lot And love the build. You have completely convinced me to do the same. I'm deciding to build a whole rack out of it, not just the initial rails. even the back ladder will be made from it. Extremely cost effective and pretty (i hope) :)

@FreedomStrider 3 года назад

That plan sounds awesome! We too are going to be building a whole rig, we just installed the initial rails for now so we can seal up our ceiling in the van. The scrapping with the card was only to get all the tape glue off the metal, and we used industrial cleaner to disolve the glue gunk. With galvanised metal, honestly, scrapping the surface was not the best way to do it, because you may too much of the galvanization. We did it very lightly so it's probably okay, but next time we would probably use just vinegar, or mineral spirits to clean the surface and because the chemicals in these solutions react with the galvanisation, this can prepare the surface to accept paint. be careful with Hammerite, the surface needs extra priming when it's galvanised otherwise the Hammerite will not stick correctly. Spray painting is a much better way to go (spray primer and anti-rust paint), a brush takes so much longer.

@DeboraWeberFicagna 3 года назад

this is exactly what I want to do, these metal bars are too big for international shipping and very difficult to find in Portugal, anyway it was a great explanation, thanks

@FreedomStrider 3 года назад

Ebay should be able to ship from the UK to Portugal - around €12 delivery (customs and shipping), a little more expensive but still might be worth it? :)

@ukjose1 2 года назад

Hi, Finally, did you use the 41mm per 41 mm unitrust to fit your solar panels or just the 41*21? Many thanks. Jose

@FreedomStrider 2 года назад

We used the 21*41 unistrut for the rails, and 21mm high Z-Brackets for mounting the solar panels (bit.ly/3ieWt0f) 👍

@ukjose1 2 года назад

@@FreedomStrider thanks for your reply. I love your videos. I am just about to fit the unitrust rail. Do you think that would be better to fit the 41*41?I would really appreciate your opinion. Many thanks

@FreedomStrider 2 года назад

You're welcome :) The 41x21 is more streamlined and just about it tall enough to lift our solar panels off the roof. The 41x41 would give more of an airgap underneath, and if you didn't want close margins then it could be a better option, I know alot of people use the 41x41 as well 👍

@cncrouterinfo 2 года назад

I actually found that 40x16 "strong" ISB aluminum extrusion is pretty much the same price (paid 80 euro for 2x3M pieces) Can be seen in my video regarding my DIY "beast" mode roofrack

@FreedomStrider 2 года назад

Yep both of them can work, as long as the metal can fit into the roof channel. Either option is cheaper than a custom made roof rack from a company 👍

@cncrouterinfo 2 года назад

@@FreedomStrider I'm currently building my DIY *steel* "beast" roof rack. If interested can check out my vid.

@edwardpeter2652 Год назад

Hi, i don't understand how you can use this kind of rails. How for example you fix a bar sise by side on those rails?

@FreedomStrider Год назад

It's a bit hard to explain...our part 2 video shows us mounting things to it (ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html) which might show it better?

@Archiez2 2 года назад

thanks

@FreedomStrider 2 года назад

🙂

@lukejones1244 3 года назад

and what if you have insulation in the van and cant access the nuts from inside?

@FreedomStrider 3 года назад

Well, this is meant to be a permanent feature but if we do come to that, we'll tackle the problem when it comes. It's really no different than how you would access a normal house's wall studs - you're going to have to remove/break stuff to get to them. In our case probably will just need to unscrew the ceiling pannels and chip out the insulation.

@sub4no 3 года назад

I cant find part 2? Looking to make something similar although my van is in use and converted and all the interior has no access to attach nuts... but I will find a way. Thanks for the video

@FreedomStrider 3 года назад

We're waiting for better weather to hop up on the roof again and start installing our solar pannels and roof deck. As for being able to attach the roof mounting rails without having access to the underneath, you could always try rivnuts. Remove the plastic plugs. If needed, extend the holes to fit the rivnuts. Rust protect. Install rivnuts. Place butyl tape or rubber washer to keep the strut from touching and rubbing on the van metal. Then fix the unistrut with bolts. (No nuts necessary on the inside) 🙂👍

@FreedomStrider 2 года назад

If you were still wondering about part 2, we (finally) released it :D --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@joshakers1 3 года назад

For future reference galvanized unistrut does not rust. Cool idea tho lots of options on rack configuration

@FreedomStrider 3 года назад

Cheers we'll bare that in mind 👍😊

@Will-zv9xh 3 года назад

Galvanised unistrut absolutely will rust. Painting it was a good move 👍🏽

@Outlander1963UK Год назад

Hi guys, can you tell me which unistrut you used please. 1.6mm light duty or 2.6mm heavey duty.

@FreedomStrider Год назад

It was the 1.6mm light duty as the 2.6mm was heavier 👍

@Outlander1963UK Год назад

@Freedom Strider And did, you find it was up to the job.

@FreedomStrider Год назад

It's still holding up and we don't see any damage or deformation. 🙂

@Outlander1963UK Год назад

@Freedom Strider Many thanks, I've ordered the light weight strut.

@angelagabriela3585 3 года назад

I love your channel Im also in the uk basically builting at the same time as you and its been so helpful 🌸✌🏽 cant wait to see the tilt mount im also wanting to do the same

@FreedomStrider 3 года назад

Thanks it's great to build together. 😃 We are designing the tilting, but first we'll sort out the heating and wiring and then we'll focus on the tilt. What van do you have?

@FreedomStrider 2 года назад

*PART 2 IS OUT* 🥳 --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@tantryl 3 года назад

Was there ever a part 2 to this? I can't find it...

@FreedomStrider 3 года назад

Not yet, we are waiting for spring to arrive here before we go on the roof again as it's bitterly cold 🥶

@tantryl 3 года назад

@@FreedomStrider Ah, thanks. I just found the channel so I've only watched a handful of vids so I wasn't sure and thought it might be rolled into one of the other videos. Custom racks seem like a near necessity for maximising solar and so few builds seem to do them. Real interested in it once you progress it... and I just saw the burnout video was posted right after I asked this :/ I'll go watch it, hope you guys are doing well.

@FreedomStrider 2 года назад

If you were still wondering about part 2, we (finally) released it :D --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@Justoutstanding Месяц назад

Butyl Tape will not crack, split or flake.

@BenBilesBB-box 10 месяцев назад

did they ever leak ?

@FreedomStrider 10 месяцев назад

Nope, no leaks 😀

@nasty.nick.p 3 года назад

You didn't need to paint the unistrut as it comes galvanized so it won't rust anyway

@FreedomStrider 3 года назад

True - we also wanted it black and not silver, but we might have cut that rambling explaining from the vid 😀👍

@tine8849 3 года назад

Yeah I thought that too but then I googled it and it seems it will rust eventually.

@jono3697 3 года назад

Good video !! But You have used far to many bolts on the unistrut, three bolts on one side would be suitable sir

@FreedomStrider 3 года назад

Well we can't be completly sure how many bolts is enough, and we don't really want to put it to the test, but the engineers we consulted did also raise the point tha the holes provided might not be enough. We thin they were, hence we used all of them 😀

@matthewshepley8298 2 года назад

Link to part 2???

@FreedomStrider 2 года назад

Part 2 is being being released this Saturday, I'll send you the link once it's released 👍🙂

@FreedomStrider 2 года назад

Part 2 is out now --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@rogerhinton3814 2 года назад

Use a box with a hole in it so your over spray of paint doesn't end up EVERYWHERE 😜

@FreedomStrider 2 года назад

Good idea, we semi stained our patio tiles with black paint 🤣

@mautay5567 Год назад

In Terminator Salvation the boss terminator was decapitated with a piece of unistrut.

@FreedomStrider Год назад

Fun fact of the day 417 😂

@jkyoft78 2 года назад

You never posted part 2??

@FreedomStrider 2 года назад

Working on it... we are releasing content as we build, so some projects are quite stretched out... Still designing the solar tilt integration with the roof rack

@FreedomStrider 2 года назад

If you were still wondering about part 2, we (finally) released it :D --> ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-zwCh9xUV_qQ.html

@jolyonlacey6930 3 года назад

looks like its already galvanised? why paint it!!!

@FreedomStrider 3 года назад

We painted for aesthetic purposes mainly. 🙂

@caleyhall 2 года назад

You’ve done all the bolts wrong, the lock washer goes on the nut then it pulls the head of the bolt tight against the washer.. Makes it easier to tighten with just one spanner in future..

@FreedomStrider 2 года назад

Yep we've realised this. All others after this are fine, but yeah...thanks 😅