Fusion-Ha! RTR Ligthbar / TrailRax Roof Rack

[GlueBoy]

Each of these lovely systems use the front windshield accessory ready mounting points and I very much didn't want to give up one system for the other. So I did some light fab work. (I am not a lawyer. This will likely void all warranties)

I replaced the 2x1 80/20 that mounts across the front with a 1x1 so that entire system could sit close to its original mounting height. I do plan on modifying the 2x1, I just need a bandsaw. The McMaster part was 4 ft. so I cut off half inch for the rail to fit, then I just tapped 1/4-20 thread along the inner circle extrusion.

I bought 2x2 L brackets and just chopped off some length on one side so that it would sit flush with the 1x1 80/20. I used the spring loaded T nuts because I was working semi blind from inside the Bronco to bolt the L bracktes in, the spring T nuts help push the threaded face up for easy install. I spaced out the four L brackets along the top finding pockets under the RTR lightbar where some rivnuts wouldn't interfere with anything. I had to go up 3 drill sizes from the 19/64" that MCM calls out on their document. I got a rivnut driver tool off amazon - there is not enough gearing down to use a drill with this so I just used a wrench to compress the rivnuts with the tool.

Once I tightened everything down it sat more flush with the top of the lightbar. I don't plan to have a tent or anything super heavy up top, I just need more cargo space when we do family activities.

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[Copperhorse73]

I hate it when mods interfere with mods. Nice piece of redneck engineering you got there, looks great

 

[NoloBronco]

Each of these lovely systems use the front windshield accessory ready mounting points and I very much didn't want to give up one system for the other. So I did some light fab work. (I am not a lawyer. This will likely void all warranties)

I replaced the 2x1 80/20 that mounts across the front with a 1x1 so that entire system could sit close to its original mounting height. I do plan on modifying the 2x1, I just need a bandsaw. The McMaster part was 4 ft. so I cut off half inch for the rail to fit, then I just tapped 1/4-20 thread along the inner circle extrusion.

I bought 2x2 L brackets and just chopped off some length on one side so that it would sit flush with the 1x1 80/20. I used the spring loaded T nuts because I was working semi blind from inside the Bronco to bolt the L bracktes in, the spring T nuts help push the threaded face up for easy install. I spaced out the four L brackets along the top finding pockets under the RTR lightbar where some rivnuts wouldn't interfere with anything. I had to go up 3 drill sizes from the 19/64" that MCM calls out on their document. I got a rivnut driver tool off amazon - there is not enough gearing down to use a drill with this so I just used a wrench to compress the rivnuts with the tool.

Once I tightened everything down it sat more flush with the top of the lightbar. I don't plan to have a tent or anything super heavy up top, I just need more cargo space when we do family activities.

Can we get a pic with the lights off?

 

[GlueBoy]

I hate it when mods interfere with mods. Nice piece of redneck engineering you got there, looks great

That's when you break out the math. Modification^(3).

 

[GlueBoy]

Can we get a pic with the lights off?

I can take different pics if you need, hadn't had a a chance to get more in daylight.

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