Re: Jamboree Rack Design
 

I spent about an hour at fab shop this morning tweakin' the design of the mounting tabs. I wanted them as flat as possible against the body for the most surface area to distribute the load. Tabs are 1 1/2"x2" and are flat on body so the load is over a large area.

Still need to get powder coated but out of time for MOAB trip. I can still access roof rack from rear bumper. I installed rack, spare, and stood on rack... minor bounce with my 200# moving up there... I plan on replacing stock carrier stubs with bolts, not comfortable with amount of thread contact on studs. It's over built, I'm sure I could trim quite a few pounds from rack with a redesign.

Fingers crossed that is stays put... time for a beer... :beerchug:

Re: Jamboree Rack Design
 

Thanks, I think I would prefer the factory hitch to this one I have, I plan on removing it for MOAB. It looks like a point of contact.

Re: Jamboree Rack Design
 

One last thing, I have a cable lock that will keep thing where they are supposed to be...:D :D :D :D :D

Re: Jamboree Rack Design
 

LOOKS GREAT! NICE JOB!!!

Re: Jamboree Rack Design
 

GREAT Job! That looks really good! :beerchug:

Re: Jamboree Rack Design
 

Anyone know how you get those goofy studs out, I tried six point sockets but it's in between metric sizes...

Replacements at 10mm 1.5 pitch 30mm long grade 8 bolts.

Re: Jamboree Rack Design
 

1/4" wrench worked for me. They were a PIA to get out, but came out eventually.

Re: Jamboree Rack Design
 

Thanks Dave, I'd feel much better if bolts and full thread contact...

Re: Jamboree Rack Design
 

Rack survived cross country to MOAB :clapping: ....

Full color and two jerry cans half full... being alittle conservative at first. I full them up all the way for trip back. Tomorrow I strap full cooler on and hit trail.

See thread in Photos...

Re: Jamboree Rack Design
 

Rack is now trail tested on Hell's and Seven Mile. Absolutely no flex in door sheet metal. Ran both trails with cooler full of ice, beer (not for trail), and food. I saw no need to take j-cans on trail, but if I was on longer trail (i.e. it would also be easier) I'd not hestiate to load her up.

Re: Jamboree Rack Design
 

SR how did you aftermarket trailer hitch hold up on the trails,Is being located under the bumper cause problems with it hanging up ?

I was thinking of having one custom installed in the bumper,It is much cheaper get a bolt on.I dont wheel as hard as you guys so I might get by with a aftermarket but I was worryed about getting hung up.

I noticed your rear plate got customized:giggling: :beerchug:

Re: Jamboree Rack Design
 

I dragged the receiver on a few obstacles but it took the punishment. I also was thinking of one custom built into bumper. I'm going to take a close look when I get home. Looking to get adventure trailer and I want receiver as high as possible.

Re: Jamboree Rack Design
 

Some local place is giving me a price,He wanted to look at a factory hitch first he's near the dealer.I got to call them back.
It looks like our bumpers would be cuts like the factory hitched bumpers..Behind bumper are square holes on the mounting brackets that are used for the factory hitch.


If he can do it cheap Ill go with the custom hitch,If he comes in high I will get aftermarket type.

Re: Jamboree Rack Design
 

Great Job!
My observations, as architect:
1. your are creating in some way a path to direct all the weight going down (as static structures should be) but remember, all the weight is "failing" on the four bolts, and there is a lot of different forces compression, extension and torque, every time that you brake, press gas, gravity, overweight, different distribution of weight, etc. my humble opinion is that for your door life, you should put over the less weight as possible in this ingenious rack, and use rather of that the roof rack for heavy weights. Orr builds inside the door a multi-forces-receiver stainless steel bar mesh.
2. At the end is not bad at all over calculate the structure in this case because who cares about 3 pounds more in a hummer, but I?m really sure that right now you can stand up three 200 pounds guys on that rack (if you are using stainless steel as I can see, maybe is aluminum and I?m wrong.
So, now you know, in the next engineering project: less metal and better forces study
Anyway looks practical and ingenious.
Keep inventing solutions, not everybody put dreams in real life, you need ba.. to do it. I love to see guys like you bringing solutions to real life

Re: Jamboree Rack Design
 

Thanks for the comments, I had a chance to use the rack at full load over the weekend with two jerry cans and full cooler. Wheeled on Drummond Island ORV trails and I can tell you that if it was goin' to fail it would of then. I have a little experience in load calculation, rotational forces, modulus, static load, etc. This proto type is over designed and I have revised plans that shave about 10# off the rack itself. I'm pleased with everything so far, we will have to see what time brings.

Re: Jamboree Rack Design
 

Well after almost a year rack and rear gate are both doing fine. I certainly used the rack as expected this past year with close to 6 weeks on the road/trail. I've had several inquires about having some made for other members, not gonna happen but I will send link to plans and instruction for a nominal donation to cover R&D. These are high quality plans and instruction that any competent fab shop would be able to build from.

If you interested just send me a PM....

Re: Jamboree Rack Design
 

After getting these plans, all I can say is WOW! Very detailed, very professional! Great work!! :beerchug:
Can't wait to get this put together and on my rig! Thanks Paul!