This has been discussed within another thread - but after not being satisfied with any of the roof rack options, and the lack of supply, I set out to build one of my own out of T-Slot framing and associated accessories.

I'm pulling together the build list, which I'll post here as well as assembly tips...it's really dead simple.






These mount points will get another nut in the roof rail to better secure the whole assembly, but I've driven it plenty with only the single point of attachment at each corner with no issue.

Now that everything is properly sized, I'll flip the entire 'platform' over so the gussets are on the underside and the entire top is flat.

 

If it connects to oem rails, that's a great design!

 

Looks like you’re in Brooklyn. 👋 from a Park Slope Defender.

 

@sblvro yes it does!

@MattEvan Hi from across the park. We're down in Ditmas.

 

Here's the parts list.



Very simple to assemble. I mounted the 6' pieces of T-Slot such that the rear would just miss the shark fin. I then infilled the horizontals cut to fit, as there's a bit of an inward canting of the roof rails from back to front - the front horizontals are shorter than the rear.

Mounting to the roof rails themselves was accomplished by grinding down the legs on these t-slot nuts from McMaster.

https://www.mcmaster.com/94750A604/






In order to secure the 3-way cubes (from 8020.net) at the corners, I simpled tapped the ends of the T-Slot framing so I could bolt through.



Next up, I plan to attach these strap down points from Front Runner, as well as these work lights from Sherpa. Two on driver and passenger side and two at the rear. Just trying to figure out wire routing...really trying to avoid drilling through the roof.

 

This is brilliant!
would love to see this in person.
hello from sheepshead bay.

 

Would be happy to show it off. We should get a socially distanced Defender group together.

 

After living with it a bit, the squared corners arent to my liking, so I've decided to fab up a part to round the corners...like so:



If there is any interest, I could fab up some more and put together a package to build out a build kit of the components.

 

Prototyping.



Working to determine whether fitting should be via tabs that slot into the T-Slot or via a sleeve that is slightly larger than the T-Slot and gets bolted through.

 

UPDATE:

I've installed the Front Runner low profile wind fairing. It certainly makes a difference and the brackets seem to be a good mounting point for driving lights should I opt to go that route down the road.

https://www.frontrunneroutfitters.com/en/u...5mm-w.html