General Roof Rack Options

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General Roof Rack Options

Phiz

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So the I guess often asked question of roof rack options for classic Pandas is showing up again I'm afraid. I've had a good dig through the forum and have seen a few different options completed and a few people who seem to have given up the trail!

What I need:
-Something I can easily mount 2 large kayaks and ideally 2 paddles to.
-Something I can complete relatively quickly.
-Something which looks as neat as possible, while being inkeeping with the panda.
-Something in the long term I can load up with gear for road trips.

Clearly the factory options are rare and getting rarer, plus the CLX ones (I think, the ones which only cover the back half of the car) don't look big enough for my requirements. I've seen Panda Panda Johns modified Berlingo rack, which looks more like what I'm after, Dragon Mans rack attaching to the door hinges which is novel but perhaps a bit more 'post apocalypse' than I'm looking for!

Given I'm going to have to drill holes in the roof (unless I worked out an arrangement off the door jambs (which I'm not sure I could get looking neat), I want what ever I end up with to be versatile and as factory looking as possible. Initially I figured I'd go down the modified berlingo rack route but a few issues came up, time, the fixed sides potentially minimising load space and also making the fixing points look as factory as possible.

Looking online for rack options for cars with no roof rails I came across systems by Rhino and Yakima where a track is riveted to the roof of the car which then accepts a range of different attachements (see pic. below).
yakima roof tracks.jpg

Now I've watched the youtube instillation video for these (going on the back of a pickup truck) and they seem to just be spreading the load across the length of the roof. They certainly don't instruct you to install it above a seam, or even along side a swage line. Issues with this seem to be you end up drilling quite a lot of holes, when you don't have a rack on the tracks look a little wrong (or would on a Panda, I think it sort of works on a pick up truck) and they are seriously expensive, especially when you consider that once you have the rails you then need specific rack fittings to go on it.

So how about fitting roof rails from another car, I realise the feet will be shaped to follow the contours of the roof but surely some out there must be close? They would sit on rubber pads so I guess new pads could be carved to fit the Panda. I had a good look on Ebay, mainly for cars with a flatish roof line but roof rails which are not too long for a Panda and came across three sets on Ebay for a Kia Carens. Clearly this is a bigger car but the bars are not full length...
Kia Roof Bars.jpg
I contacted the seller of the cheapest set (pictured) who confirmed the overall length of these roof rails are 120cm, so just short enough for the roof of a Panda, I also asked for the width of the mounting feet, that got lost in translation but I did get some to be fair more usefull info, that the gaps between the feet are 40cm and 32cm. I'd guess from that the middle mount would be say 5cm, so if I fitted these rails and then clipped on my standard roof bars they could be 75cm apart, not the greatest of spans (compared to my Volvo roof rails) but I would guess far enough apart to secure our boats! The actual mounts look pretty big, which although shortens the useable length of the bars does mean that the weight could be spread as much as possible across the roof of the car (as does the extra central mount, which many do not have and really would not get in the way at all).

So what do you recon, a quick and easy solution for getting the boats on the roof with the option to fabricate an adventure roof rack at a later date which simply bolts on or a terrible idea which either would not fit, would look terrible or even worse would not be structurally strong enough to carry any real load?

And to close on a bad pun, Show me pics of your racks(y)
 
We have made a custom rack our selfs but requires welding skills it then bolts directly to the corner section adjacent to the seams also picking up the rear Sisley roof fixings poly nuts ( pop riveted nut inserts ) in 4 locations to take the load
 
We have made a custom rack our selfs but requires welding skills it then bolts directly to the corner section adjacent to the seams also picking up the rear Sisley roof fixings poly nuts ( pop riveted nut inserts ) in 4 locations to take the load

I've welded up roof racks before for cars with gutters etc. so no problems there. Any pictures of your rack? Can you point me towards a thread from when you made it?

What do you make of the possibility of fitting the Kia roof rails? I've not taken the headlining out of mine yet so not sure what would be considered strong enough and what wouldn't. I think ideally I'd like the mounting pads to sit over the seams either side but can't see I'll be able to make the Kia ones do that. The Ebay listing below shows how they attach to the car.

http://www.ebay.co.uk/itm/2004-KIA-...098036?hash=item1a2b5459f4:g:yOwAAOSwcgNZC5UV
 
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the only problems with my rack is that it was done very quickly, without taking any measurements, built on the car in situ, and it looks a mess.
i also didnt build it out of the best tubing.. it was all built from an old caravan awning.

it survives my weight pressing down on it though, and provides an awesome place to mount spot lights / aerials and luggage!

the berlingo rack looks really nice on a panda.. i always have my eyes open for one.
 
the only problems with my rack is that it was done very quickly, without taking any measurements, built on the car in situ, and it looks a mess.
i also didnt build it out of the best tubing.. it was all built from an old caravan awning.

it survives my weight pressing down on it though, and provides an awesome place to mount spot lights / aerials and luggage!

the berlingo rack looks really nice on a panda.. i always have my eyes open for one.

Looks right on Project Fallout though! Plus as you say suits it's purpose too. From the pictures I've seen the Berlingo racks do look spot on once fitted, my only concerns on them are how they are secured to the roof (as with Kayaks I'd be a little worried they might catch the wind at speed and rip the rack off the roof if not well secured) and the height of the side rails, looks great but I think I might need to occasionally overhang the sides of the rack which would be easier if the rails were lower.

If I can get and fit roof rails in the next couple of weeks then I can use the Panda for a trip to south Wales, if not I'll take the volvo and then I've got a lot more time to completely fabricate a rack from scratch if required.
 
I've welded up roof racks before for cars with gutters etc. so no problems there. Any pictures of your rack? Can you point me towards a thread from when you made it?

What do you make of the possibility of fitting the Kia roof rails? I've not taken the headlining out of mine yet so not sure what would be considered strong enough and what wouldn't. I think ideally I'd like the mounting pads to sit over the seams either side but can't see I'll be able to make the Kia ones do that. The Ebay listing below shows how they attach to the car.

http://www.ebay.co.uk/itm/2004-KIA-...098036?hash=item1a2b5459f4:g:yOwAAOSwcgNZC5UV


Yep it's in Brian the BFP. The finished item we used 20 mm conduit bent up and welded then some poly nuts inserted into the roof if you want to borrow the Bender and riveter your welcome. Or pop over and I could bend up the basics for you !!
 
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Yep it's in Brian the BFP. The finished item we used 20 mm conduit bent up and welded then some poly nuts inserted into the roof if you want to borrow the Bender and riveter your welcome. Or pop over and I could bend up the basics for you !!

Cheers for that, just found some photo's of the rack you made in the older thread about all three Panda's, does look class, light bar might be a nice edition if I do install a bigger alternator too!

May well take you up on your offer, did you use 20mmx2mm conduit? If this is the route I go down then there is no rush as I'll not get time between now and the kayaking trip to make it, though even if I do fit Kia roof bars in the long run I'll still want a cargo cage type arrangement to bolt to that and it'd look so much smarter with the corners rounded off:D.

Have you got any pictures of your mounting points?
 
Cheers for that, just found some photo's of the rack you made in the older thread about all three Panda's, does look class, light bar might be a nice edition if I do install a bigger alternator too!

May well take you up on your offer, did you use 20mmx2mm conduit? If this is the route I go down then there is no rush as I'll not get time between now and the kayaking trip to make it, though even if I do fit Kia roof bars in the long run I'll still want a cargo cage type arrangement to bolt to that and it'd look so much smarter with the corners rounded off:D.

Have you got any pictures of your mounting points?


IMG_1494676110.530720.jpgIMG_1494676130.680716.jpg
It would be possible to make a rack just for the kayaks which could have the same fixings as a General purpose rackIMG_1494676664.800199.jpgIMG_1494676676.064004.jpgIMG_1494676688.417747.jpg
 
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View attachment 180399View attachment 180400
It would be possible to make a rack just for the kayaks which could have the same fixings as a General purpose rackView attachment 180401View attachment 180402View attachment 180403

Those riveted nuts do look like a smart option. I agree possibly two racks might be the way to go, though this is one reason why I was hoping I could sort some roof rails, then I could use my standard bars for the Kayaks and make something cool for the rest of the time (y). Main issue I can see with that is there would not be space outside the seems (or least I doubt there would be) so the mounts would have to go on the main roof panel. I don't know how strong that would be (compared with right on the edge like your fixings) and also it would potentially mean my finished rack would be narrow and have a lot less storage potential.
 
Those riveted nuts do look like a smart option. I agree possibly two racks might be the way to go, though this is one reason why I was hoping I could sort some roof rails, then I could use my standard bars for the Kayaks and make something cool for the rest of the time (y). Main issue I can see with that is there would not be space outside the seems (or least I doubt there would be) so the mounts would have to go on the main roof panel. I don't know how strong that would be (compared with right on the edge like your fixings) and also it would potentially mean my finished rack would be narrow and have a lot less storage potential.


Personally I would think it's a mistake to try to fix to the roof without additions to the structure from underneath composite sections at the corners with folds are 500% stronger every time a fold is added it doubles the strength how about this option IMG_1494694567.847347.jpg or something on those lines
Best to use non galvanised conduit then get it plastic coated
Kelcoat in leek are a good option
 
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Personally I would think it's a mistake to try to fix to the roof without additions to the structure from underneath composite sections at the corners with folds are 500% stronger every time a fold is added it doubles the strength how about this option View attachment 180405 or something on those lines
Best to use non galvanised conduit then get it plastic coated
Kelcoat in leek are a good option

Yeah looking at that sketch I realise the Kia roof bars would never look as cool, even if fitted in a secure way! That being said my last contact with the seller was asking for lowest price, if it comes back real low I may still go down that route!

It certainly makes structural sense to put the mounts right out in the corners as you say, plus it means the roof rack could potentially be quite a bit larger without looking wrong/overhanging the fixings (dimensions on sketch pretty usefull). By dipping the front and back rails for the boats I could possibly get one rack serving both purposes too, guess I'll measure up the peli-cases I've got and see what would be a good fit there.

One other consideration though is the rivet nuts, well more to the point the sheet metal they'll attach to. Given it is so thin (I'd guess 1.2mm or similar there) I'd still have a nagging doubt about the boats acting as a sail and ripping them out (something I've seen on factory roof rails) so would really prefer to have some kind of washer/backing plate on the inside but gather access would be restricted (possibly why the factory roof bars have retaining nuts designed to fit in slots?).

Welcome your thoughts on this, I'll measure up car/boats and kit in the next few days and go from there. :D
 
Yeah looking at that sketch I realise the Kia roof bars would never look as cool, even if fitted in a secure way! That being said my last contact with the seller was asking for lowest price, if it comes back real low I may still go down that route!

It certainly makes structural sense to put the mounts right out in the corners as you say, plus it means the roof rack could potentially be quite a bit larger without looking wrong/overhanging the fixings (dimensions on sketch pretty usefull). By dipping the front and back rails for the boats I could possibly get one rack serving both purposes too, guess I'll measure up the peli-cases I've got and see what would be a good fit there.

One other consideration though is the rivet nuts, well more to the point the sheet metal they'll attach to. Given it is so thin (I'd guess 1.2mm or similar there) I'd still have a nagging doubt about the boats acting as a sail and ripping them out (something I've seen on factory roof rails) so would really prefer to have some kind of washer/backing plate on the inside but gather access would be restricted (possibly why the factory roof bars have retaining nuts designed to fit in slots?).

Welcome your thoughts on this, I'll measure up car/boats and kit in the next few days and go from there. :D


Points taken a 4 mm thitck tapped plate could be slid inside the top d section the kept in place with a csk bolt in 6 positions 2 on the tail gate 4 on the d section
Sj
 
Points taken a 4 mm thitck tapped plate could be slid inside the top d section the kept in place with a csk bolt in 6 positions 2 on the tail gate 4 on the d section
Sj

Problem solved I'd say:D. I'll get measuring up and draw out what I think I need.
 
Ok no probs if you get the radius or template it can be bent up to your required sizes conduit comes in 3.6 Mtrs lenghts add 20 % for waste. Draw it up and I will bend it for you and fit an poly nurts
 
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Sounds like you have it sorted, but here's the one I have for sale if anyone else is interested. I paid 50 for it but got another one I liked better so 50 takes it. It's really solidly built, needs a good clean mind you.


That's a bargain ready made looks solid sj
 
Well now I've got a dilemma! I've spent half the day thinking through what I want and how it could work, think I've got an idea in my head that'd be pure class and then I come on here... £50 sounds like a very fair price and I am short on time... will discuss with my other half and work out what to do tomorrow! Looks a good size too, a few things I'd probably have done a little differently, though I'd not thought to slope the front edge, bit of perspex on there as a wind deflector might help things along a little too.

I'd spent a while trying to work out how low the front and back would need to be for the boats, based on them going on upside down, as I normally would on flat bars, then I realised that if I mounted them vertically they would be nice and narrow and as they thin front and back they could sit on a rack with bars all the way around to a good height! So I can make (or buy) a badass looking cargo cage and as long as I've got bars in place to fit vertical bars to strap the boats to, like the yellow boat below:

maxresdefault.jpg

Given the length of our current boats we could possibly even just bolt the uprights to the front and rear bars of the roof rack!
 
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