Jeep Wrangler TJ - Custom Overland Roof Rack Build | DIY

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I needed a very specific Roof Rack for my Jeep Wrangler TJ that I couldn't find online. So I decided to build my own Custom Overland Roof Rack that fit my needs perfectly. I haven't found many videos covering the actual design and build process for TJ roof racks so I hope this will help anyone else that is looking for something similar. This build probably took me about two weeks to finish. I am super pleased with how it turned out. I drove all the way from Ohio to Moab and back doing hard badge of honor trails along the way. The rack held up great with zero issues!
Amazon Affiliate Links:
1/4 Gussets used for Rack Interface - amzn.to/3PqzrCZ
Swag Offroad Square Tube Roller Dies - amzn.to/3PxQUcN
KC Light Mounts - amzn.to/3rqp9L2
Small Gussets - amzn.to/3ETkPHn
Kobalt Angle Grinder - amzn.to/3Lz9Feu
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Contents
00:00 - Intro
01:00 - Materials & Tools
04:08 - Making the Front Mounts
12:26 - Hardware
13:56 - Making Rear Mounts
20:54 - Bending/Marking/Adjusting Mounts
28:22 - Welding Rack Interface onto Mounts
29:48 - Building the Rack
35:51 - Roof Rack Walkaround
38:56 - Outro
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2004 Jeep Wrangler Sport
4.0 Straight 6 engine
5 Speed Manual Transmission
Dana 44's Front and rear (4.10 gears)
ARB Air Lockers Front and rear
Rubicon 241 Transfer case (4:1 gear ratio)
Jeep Mods
3.5" Metalcloak Dual Rate Springs (Front)
4.5" Metalcloak Dual Rate Springs (Rear)
35" Mickey Thompson Baja Boss M/T
15" Fuel Covert Wheels
Poison Spyder Steering Box Skid Plate
Savvy Cable Shifter
LoD Offroad Signature Series Rear Bumper with Tire Carrier/Jerry Can Mount/Cargo Rack
Quadratec QRC front bumper (cut into stinger style)
Metalcloak Rocker Rails
Metalcloak Extended Corner Guards (Aluminum)
MetalCloak Overline Fenders (Aluminum)
Metalcloak 4" Fender Flares (Front and Rear)
Smittybilt X20 Winch with Synthetic Rope Line
M.O.R.E oil pan/Tranmission skid plate
ARB Air Lockers (Front and Rear)
ARB High Output On Board Compressor
Fox Performance Series 2.0 Shocks
StinkyFab Heavy Duty Aluminum steering
Teraflex Heavy duty ball joints
Poison Spyder Diff Covers (Front and Rear)
Ten Factory Chromoly axle shafts (Rear)
Motive Gear Chromoly Axle Shafts (Front)
M.O.R.E "Bombproof" Motor Mounts with 1" of lift
Ecotric Vented Hood Louver
Decals from Pixel Decals
Hooke Road Interior Cargo Rack
K&N High Performance Air Filter
LED dash/over head lights
Ampper LED Rock Lights
DEI Fuel Rail Heat Sheild
Savvy Aluminum Fuel Tank Skid Plate
Bosch 4 Hole Upgraded Fuel Injectors
Motobilt Tub Armor (Aluminum)
Motobilt Half Door Armor (Aluminum)
Dana 44's Swapped From A Rubicon (Front and Rear with 4.10 gears)
241 Transfer Case Swapped From a Rubicon
Clayton Adjustable Control Arms (Full Set)
Barnes 4WD Transfer Case Skid Plate
Custom Adams Driveshafts (Front and Rear)
Bestop Supertop NX Soft Top
SpeedoHealer (PolyPerformance)
Redhead Steering Gearbox
SwayLoc Dual Rate Sway Bar
MicTuning J1 Phosphorus Headlights
Hooke Road Over Head Molle Panel
Hooke Road Tailgate Table
Custom Built Roof Rack (by me)
Inspired Overland Roof Top Tent
Vanco Big Brake Kit with Black Magic Brake Pads
Mic Tuning J1 Phosphorus Headlights

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Опубликовано:

22 июл 2024

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Комментарии : 47

@jedeckerd5969 10 месяцев назад

Amazing work and looks great. Bonus with the rack itself it’s a great place to mount some lights to make camp setup easier at night . The front is a perfect spot for a light bar.

@WheelinWithWally 10 месяцев назад

Thank you! I really like how it came out. Its stronger than most you can buy and I think it looks better too. I actually have considered doing some lights around the rack for a 360 degree zone of coverage with switches for each side. I just can't really mount anything over the rack or I wont be able to fit into my garage anymore. I am also planning to add an awning and am looking into the tanks of water to mount on it for camp showers and dishes ect while camping. Then I can ditch the water jerry can and add another fuel jerry can.

@jedeckerd5969 10 месяцев назад

@@WheelinWithWally that is a great plan. My favorite part about your videos is the fact that you figure it out in a true DYI fashion. With the space between the Jeeps top and the rack I’m sure you’ll find it useable space for lights or something without adding height

@WheelinWithWally 10 месяцев назад

@@jedeckerd5969 I wanted to put in so much more info that I did film but the video was crazy long. I cut out so much just to shorten it to 39 minutes. Long videos just do not do well on youtube. Thats why most people make really short 15 min videos. That gap between the rack and top is my plan. I don't want anything sticking out past the rack for when I am offroading. I want to keep it as capable as I can and keep the footprint small. Thats my current hold up with the camp shower. I cant find one small enough to fit where I want it too. I want to get that stuff on before I add the lights so i know where they can fit.

@jedeckerd5969 10 месяцев назад

@@WheelinWithWally space is definitely a premium, and every addition needs a lot of attention

@eversleyowl 10 месяцев назад

@@WheelinWithWally I understand that longer videos may not do so well on RU-vid in terms of views, but please be assured those of us with a real interest in our Jeeps really do appreciate them.

@vetguy2562 10 месяцев назад

Oh, don't forget you can always let a little air out of the tires to get just a bit more clearance too 😁👍

@wextremeart4399 6 дней назад

Can't see bend beautiful work

@WheelinWithWally 6 дней назад

@@wextremeart4399 Thank you!

@ajpedals7196 10 месяцев назад

For those A pillar bolts, I put a good quality torx socket in them and gave each about 5 food whacks with a hand sledge. Breaks all the rust and loctite and saves the paint

@WheelinWithWally 10 месяцев назад

I had not tried that method. I have an affinity for fire and my paint doesn't concern me much now but that's a great tip for the people who do! Thanks

@ryansremark6983 10 месяцев назад

Man you’re by far the best current TJ content creator, Used you’re axle/tc swap videos as guides when I swapped mine in.

@WheelinWithWally 10 месяцев назад

Thanks man! I appreciate that. It's hard out here trying to grow a small TJ RU-vid channel lol. What did you swap in on your TJ?

@ryansremark6983 10 месяцев назад

@@WheelinWithWally same as you, rubicon Dana 44s with the 241 transfer case, still tinkering with the wiring to setup the original pumps that came with axles. I went with a Currie 4 inch lift, adjustable arms. Welded brackets w/ Johnny joints to the front diff etc etc. the build never ends, oh and a Garvin roof rack, though I appreciate the effort building it yourself.

@WheelinWithWally 10 месяцев назад

@@ryansremark6983 that's awesome man you are going to love it! I would have probably gone with the garvin if it would've worked with my rear bumper. It looks good. You're right though, it never ends lol

@tdg0101 Месяц назад

Nice job.

@WheelinWithWally Месяц назад

Thanks!

@UncleDirtFarm 10 месяцев назад

wet newspaper is a good heat shield

@WheelinWithWally 10 месяцев назад

Makes sense! I'll remember that thanks

@eversleyowl 10 месяцев назад

@@WheelinWithWally I can't weld, but this summer on holiday we watched some glass blowers at work, they used their bare hands holding wads of wet newspaper to shape the molten glass. So I have no doubt @uncledirtfarm is spot on with that tip!

@WheelinWithWally 10 месяцев назад

@@eversleyowl that's pretty awesome!

@ORJeeper 3 месяца назад

On my 2004 TJ , After stripping out one of the A pillar bolts I used a soldering iron to heat up the bolts and they came right out.

@WheelinWithWally 3 месяца назад

That's awesome. Those can be a nightmare when they strip out.

@terrykinnell4201 Месяц назад

nice job!

@WheelinWithWally Месяц назад

Thank you!

@bernardaborita4631 10 месяцев назад

This is another awesome video!! 👌

@WheelinWithWally 10 месяцев назад

Thanks man! I appreciate that. This one took a long time to edit because I filmed so much over like 2 weeks. So I'm happy to hear it came out decent

@JoshtheSwift 10 месяцев назад

That rooftop tent looks like more than enough room for 2 people to comfortably sleep in without cuddling lol.

@WheelinWithWally 10 месяцев назад

Possibly, but you'll never know 😉 lol

@long-jeep 10 месяцев назад

Another cool project. It should really work out great on your camping trips.

@WheelinWithWally 10 месяцев назад

Thanks! It's was a real game changer on this trip to Moab I just did. Not having to carry a tent inside freed up some much needed space.

@lanceyoder1971 10 месяцев назад

Great video man! Very glad you gave me the link on Facebook. For your first time building something like this, you did great! Your metal bowed because of heat... A lot of the time you can clamp it down to weld it so that doesn't happen and then let it cool. Great job and I look forward to seeing your build grow 🙂

@WheelinWithWally 10 месяцев назад

Thanks! I'm glad you checked out the channel and I appreciate the tip!

@eversleyowl 10 месяцев назад

Another great video, really admire thart you are willing to bring us along for the journey on things that are a learning curve for you. If it were me I would pull the rack off other than when it was needed, as I prefer the look of your Jeep without it. It will be interesting to hear how you find the Jeep is offroad once you have the tent on top and the centre of gravity is much higher.

@WheelinWithWally 10 месяцев назад

I thought about that but I'm to lazy to take off and put it back on. Plus I don't want to have to store it somewhere if I take it. I outgrew my garage years ago lol. But to answer that last part of your comment, I have since taken the jeep with the rack and the tent on all the way from Ohio to Colorado and the Utah. I drove it the entire way and kept them on while I did multiple badge of honor trails with no issue. Honestly didn't really even notice it up there or feel a difference offroad.

@stephenskwaryk9665 10 месяцев назад

If you use a wrench to outline the bolt it helps to contain the heat when you heat up those bolts.

@WheelinWithWally 10 месяцев назад

Do you mean using the box end of a wrench to go around the bolt while you heat it?

@user-io2wv7wy5p 2 месяца назад

Would a chop saw and medal blade be worth investing in for this? Seems that would have helped. Turned out great. Nice work and thanks for sharing!

@WheelinWithWally 2 месяца назад

Oh yeah that would probably help a bunch. Thank you!

@vetguy2562 10 месяцев назад

That's awesome 😎👍 I think it was the right choice to add the Grade 8 hardware too, it's never going to fail 🤘😎 How did it feel with the tent up top like that, you didn't forget about being up there after the first night did you? Just kidding, it really is cool, and it's great to see you making videos again 😁👍

@WheelinWithWally 10 месяцев назад

That tent with this rack is awesome. I didn't lose much clearance and it's so light you barely notice it. I'm a huge fan. Thanks for kind words!

@vetguy2562 10 месяцев назад

@@WheelinWithWally Of course, I totally dig your content 🤘😁

@dougphillips8389 10 месяцев назад

That job looked exhausting.. but man did you do a fine job. Wished I had the fabricating mindset to attempt something like that. GREAT JOB! I suppose your going to paint or rhino line the rack?

@WheelinWithWally 10 месяцев назад

I did awhile ago. I just used some self etching primer cans from lowes and then spray can bedliner. Actually looks pretty good and worked pretty well. And hey just give it a go. I'd never done that before and trust me I did not know what I was doing most of the time lol

@S.-.V 10 месяцев назад

You’re putting a ton of weight on mounts and bolts that were not meant to support that weight…

@WheelinWithWally 10 месяцев назад

That's true but I keep an eye on it. I've gone well over 4k miles now and most of that was on a fairly extreme road trip from Ohio to Colorado and then Utah doing some very hard badge of honor trails all while having the rack and tent on. Not a single crack or loose bolt after all of that. I replaced all of the stock hardware with grade 8 bolts that I think are more than strong enough to handle the weight. The front kc mounts were my main concern but I kept the bar I welded on as close to the back of the mount to keep any extra stress from leverage off of it while also reinforcing it with gussets. While I am not an engineer and didn't calculate strengths and stresses I will add this: On the trip I previously mentioned my rack was completely solid with zero issues after all of the trip. My buddy who did the trip with me purchased a garvin roof rack that was designed by professionals. He had multiple issues with the rack swaying and rocking and even causing multiple large dents in the body of his JL. Take that for what you will. All I know is what I can provide from the experience I've had with it and also mention that all of the metal is thicker and stronger on my rack than what comes on the roof racks I've seen that you can purchase.