Thinking of making my own roof rack / moon roof

[300winmag]

Hey guy's, couple questions for you but first here's the low down. Never done anything like this before but I can mig weld aluminum and I'm down for learning.

 

The only thing I use my NV for is camping and towing my rzr, that being said I just drove up to Haida Gwaii for camping and just as I thought... I need more light and an awning.

I am thinking of doing the "usual" rack like 8" tall with aluminum tubing and cross bars.

I would be putting six 7" 50watt single LED lights on the fronts for throw and one 8" light bar on the sides and rear for occasional use with a 12' awning on the passenger side.

I would like to make a ladder so I can crawl up there and star gaze but I dont think the rack supports will hold the weight of 2 people standing and moving up there so my other option is to start gaze from inside the van(where we sleep) and get a big moon roof put in the back. I looked and it seems the vents are in the way though... thoughts? I would also like to put a camper vent in the roof with a screen... dunno where yet.

 

Does anyone know what the weight limit is for the roof? and would that number have to be divided between all mounting points? When I stand up like to get off the roof my weight will be on the back 2 supports only and I don't know if they will hold or not.

 

Any thoughts or opinions would be appreciated :)

 

[radin2son]

Nihil_Perdidi (think I got that right) installed a boat hatch that should be just what you want. Some questioned the placement location and need for reinforcement. It, however, would not get in the way of the rack. Check for "Relevant notes..." under conversions.

 

The Beast just posted photos of his rack and others have posted good info as well.

Edited August 4, 2016 by radin2son

[ASD Dad]

If you use the mounting points up there it will be plenty strong enough for people.  My Topper steel tube rack is rated for 500 lbs with two mounts and 750 lbs with 3 mounts used.  That is 2 factory mounts so 4 actual standoffs or 6 for the 3 mount.  

 

Others like Aluminess use several mounts and I think The Beast custom rack used every mount up there!  He is down in FL and had a boat ladder specialist make his rack custom.  

 

Regardless the rack should be plenty strong enough for people walking around.

[KMG]

Keep in mind you can build the rack with a piece of rectangle tubing running front to back on each side and use every van mount regardless of how many cross bars you use.  This also allows you to choose how the crossbars are spaced apart.  Use 1" x 3" tubing and installing the 1" side to the van mounts then the 3" side gives you the clearance so the crossbars clear the roof pitch.  Double check that 3" is enough so the crossbars clear.  Just a thought.  Post pics.

[300winmag]

Thanks for the replies guys. After reading a bunch on the topic I think i might go without the moon roof as I am hearing nothing but bad stories and the glass I want would be twice the size I am reading about so it's probably a better idea to just stick with the vent and star gaze on top of the roof. Especially now that I know it can hold our weight. That said I think I have found a nice awning, the Fiamma F65S 370 deep black fits the bill perfectly.. except the fact I am mounting the awning to the roof rack not the actual van and the mounting hardware is round for a van...

[300winmag]

So I am ready to purchase the aluminum tubing and the lights but before I do what is our alternator rated for? I cannot find it on the google, manual or service manual. I am using six 50 watt leds plus another 100 watts or so for the back and sides....I am thinking about switching the headlights/tail lights and interior lights to led to save energy but might just install another battery just to be careful. Who's in the know?

[300winmag]

Well I ordered the lights... I will have 30,000 lumens in perfect reflectors for hwy driving. Got the aluminum diamond checker plate, tubing, angle bar and flat bar. I hope this weekend i can start my build! Thinking about upgrading the headlights to them opt7 led lights also.