Vigo DIY Frontrunner Roofrack Installation

Members' DIY projects
Post Reply
User avatar
DerikB
High Range 4WD
High Range 4WD
Posts: 61
Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2018 Hilux 2.8 XtraCab 4x4 Auto
Real Name: Derik
Club VHF Licence: HC143

Vigo DIY Frontrunner Roofrack Installation

Post by DerikB »

From this thread: viewtopic.php?f=94&t=37296" onclick="window.open(this.href);return false;

After selling my Pajero, I was stuck with a large Frontrunner Roofrack (2150mm x 1225mm).
I tried to sell it in order to buy a new one for the Hilux, but after not getting it sold, decided to keep it and modify it!

It all started here:
0.JPG
0.JPG (251.23 KiB) Viewed 7666 times
It was easy to shorten as I only had to cut the two long side rails. Very nice idea of Frontrunner to make it modular - All the other slats and spares that are left could easily be used to construct another with only minor part purchases. On the Pajero it had 6 legs, two longer ones in the front and back and then two shorter ones in the middle. I only used the longer ones.

I finished the roofrack and decided I needed to fit it this weekend in preparation for our upcoming Namibia trip in December. I got on the phone with my buddy Monsterlux and quickly bribed him with a few cold ones for his assistance.

First we had to remove the rubber strips in the channel and properly clean it.
1.JPG
(106.58 KiB) Downloaded 537 times
After a lot of measuring and positioning, we decided to cut the tracks the same length as the roofrack and to position the rails 170mm from the windscreen.

It was then time to drill the first holes!

I received some touch-up paint with the Hilux, so we put it to good use.
2.JPG
2.JPG (57.25 KiB) Viewed 7666 times
We decided to use Riv nuts, because this roofrack will only be used for my solar panel and it was a major job to strip the cab and to remove the rooflining. From experience there will also always be new rattles when doing that! We decided on 3 riv nuts per side.
3.JPG
3.JPG (61.18 KiB) Viewed 7666 times
Then we added some silicone to the holes - For sealing and also to make it harder to rattle loose.
5.JPG
5.JPG (47.33 KiB) Viewed 7666 times
We then worked towards the back following the same process for the other 2 holes.
4.JPG
4.JPG (78.67 KiB) Viewed 7666 times
We replaced the factory rubber strip and drilled holes into it to match up with the riv nuts.
6.JPG
6.JPG (67.5 KiB) Viewed 7666 times
A fellow clubmember, Rod, gave me advice to use insertion rubber under the tracks. Because the inner side of the roof is lower than the outside.
That was cut to size and the corresponding holes made
7.JPG
7.JPG (75.98 KiB) Viewed 7666 times
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
Image
ORRA VHF Call Sign: B78
User avatar
DerikB
High Range 4WD
High Range 4WD
Posts: 61
Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2018 Hilux 2.8 XtraCab 4x4 Auto
Real Name: Derik
Club VHF Licence: HC143

Re: Vigo DIY Frontrunner Roofrack Installation

Post by DerikB »

All that was left was to align the track and to tighten the bolts!

Then we lifted my newly modified roofrack on, installed the tracks and tightened everything up!
8.JPG
8.JPG (117.82 KiB) Viewed 7661 times
9.JPG
9.JPG (103.99 KiB) Viewed 7664 times
10.JPG
10.JPG (98.04 KiB) Viewed 7664 times
11.JPG
11.JPG (90.3 KiB) Viewed 7664 times
I am glad to report that it still fits into my garage! (just!) :yahoo:
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
Image
ORRA VHF Call Sign: B78
User avatar
MonsterLux
Low Range 4WD
Low Range 4WD
Posts: 216
Joined: Tue Jan 24, 2012 12:35 pm
Town: Witbank
Vehicle: 92 Toyota Hilux
Real Name: Johan
Location: Mpumalanga

Re: Vigo DIY Frontrunner Roofrack Installation

Post by MonsterLux »

Neem kennis van die dak lig se draad aan die regter kant reg onnder die eerste gat van die windscreen af
User avatar
DerikB
High Range 4WD
High Range 4WD
Posts: 61
Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2018 Hilux 2.8 XtraCab 4x4 Auto
Real Name: Derik
Club VHF Licence: HC143

Re: Vigo DIY Frontrunner Roofrack Installation

Post by DerikB »

Ja, goeie tip. Ek het ongelukkig deur hom geboor, nou werk die agterste courtesy light nie meer nie. Maar ek sal dit patch.

Volgende DIY job gaan wees om n "skeleton" in die Beekman Fibreglass canopy te bou om hom genoeg te versterk om my RTT te dra!


Sent from my iPhone using Tapatalk
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
Image
ORRA VHF Call Sign: B78
User avatar
Froll
Monster Truck
Monster Truck
Posts: 3305
Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 2010 4.0 V6 Fortuner 4x4
Real Name: Roger
Club VHF Licence: N/A

Re: Vigo DIY Frontrunner Roofrack Installation

Post by Froll »

Job well done. Looks very good. :thumbup: :thumbup:
User avatar
4x4BEES
Monster Truck
Monster Truck
Posts: 3447
Joined: Wed Nov 20, 2013 10:13 am
Town: Brackenfell
Vehicle: Hilux 4.0V6
Real Name: Kevin

Re: Vigo DIY Frontrunner Roofrack Installation

Post by 4x4BEES »

Awesome :thumbup:
User avatar
barleigh
High Range 2WD
High Range 2WD
Posts: 15
Joined: Wed Jul 23, 2014 7:45 pm
Town: Durban
Vehicle: 1995 2.4P Toyota Hilux Raider Dbl Cab - 22R
Real Name: Barend

Re: Vigo DIY Frontrunner Roofrack Installation

Post by barleigh »

Looks great! What size panel do you have there, a 90W or bigger?
User avatar
george
Monster Truck
Monster Truck
Posts: 6565
Joined: Wed May 23, 2007 11:16 am
Town: Velddrif
Vehicle: Triton 3.5l V6
Real Name: George
Club VHF Licence: HC107
Location: Velddrif
Contact:

Re: Vigo DIY Frontrunner Roofrack Installation

Post by george »

Nice Derik :thumbup: Did the riv nut tool work easy enough?
I am contemplating the same thing, but was warned that the tools like the one you used does not really do the job.
"The World is a book, and those who do not travel read only a page.-Saint Augustine"
User avatar
DerikB
High Range 4WD
High Range 4WD
Posts: 61
Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2018 Hilux 2.8 XtraCab 4x4 Auto
Real Name: Derik
Club VHF Licence: HC143

Re: Vigo DIY Frontrunner Roofrack Installation

Post by DerikB »

Hi George

Yeah I'm happy with the outcome, the riv nuts we used expanded very well and I'm not concerned about them breaking off.

No rattles or anything that I should be worried about.

I won't load a RTT or Jerrycan's onto it with the rivnuts, but I only use it for the Solar Panel - so I believe in my application it will last.

We're off to the Kgalagadi in two weeks with the notorious corrugated roads, so I will be able to tell you next year if it fell off :laugh2:
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
Image
ORRA VHF Call Sign: B78
User avatar
DerikB
High Range 4WD
High Range 4WD
Posts: 61
Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2018 Hilux 2.8 XtraCab 4x4 Auto
Real Name: Derik
Club VHF Licence: HC143

Re: Vigo DIY Frontrunner Roofrack Installation

Post by DerikB »

barleigh wrote:Looks great! What size panel do you have there, a 90W or bigger?
Hi Barend

It's a 80w Solarworld panel. 950 x 680mm. Weight around 8kg.
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
Image
ORRA VHF Call Sign: B78
User avatar
Masekind
LR4WD, Lockers, Crawler Gears
LR4WD, Lockers, Crawler Gears
Posts: 1235
Joined: Mon Feb 18, 2013 11:41 am
Town: Lichtenburg
Vehicle: 2005 Hilux 4x4 v6, LR tank, ARB Bumper. (iJzer)
Real Name: Drikus
Location: Lichtenburg

Re: Vigo DIY Frontrunner Roofrack Installation

Post by Masekind »

Nice gedoen
If you don’t build your dreams someone else will hire you to build there’s
Image
User avatar
coetzer94
Low Range 4WD
Low Range 4WD
Posts: 228
Joined: Tue Nov 18, 2014 9:13 pm
Town: Pretoorsdorp
Vehicle: Silver Hilux DC 2.8 GD-6 2016
Real Name: Vian

Re: Vigo DIY Frontrunner Roofrack Installation

Post by coetzer94 »

Ek weet die is n ou draad, maar hoe het daardie rivnuts gehou in die kalahari? Ek wil ook n Roof rack op die trokkie sit maar eks bekommerd oor rivnuts, veral as ek gereeld die rak wil afhaal en terug sit.

African outback het in die verlede sulke staal blokkies gehad wat mens permanent teen die dak vas bout en dan getapte gate aan die bokant het vir die roof rack "voetjie" om aan vas te bout. Ek dink dit gaan beter werk veral as mens nie die rak permanent op hou nie. Ek dink ook hulle gaan beter gewig dra as die rivnuts?

Weet iemand dalk wie sal sulke blokkies vir my kan maak?
--------------------------------------------------------------------------------------------------------------------------------

Working on my bucket list only makes it longer
User avatar
Henry Greeff
Newbie
Posts: 2
Joined: Mon Apr 23, 2012 1:37 pm
Town: Kuruman
Vehicle: Hilux
Real Name: Henry

Re: Vigo DIY Frontrunner Roofrack Installation

Post by Henry Greeff »

coetzer94 wrote:Ek weet die is n ou draad, maar hoe het daardie rivnuts gehou in die kalahari? Ek wil ook n Roof rack op die trokkie sit maar eks bekommerd oor rivnuts, veral as ek gereeld die rak wil afhaal en terug sit.

African outback het in die verlede sulke staal blokkies gehad wat mens permanent teen die dak vas bout en dan getapte gate aan die bokant het vir die roof rack "voetjie" om aan vas te bout. Ek dink dit gaan beter werk veral as mens nie die rak permanent op hou nie. Ek dink ook hulle gaan beter gewig dra as die rivnuts?

Weet iemand dalk wie sal sulke blokkies vir my kan maak?
Kan jy dalk verduidelik hoe werk die blokkies presies


Sent from my iPad using Tapatalk
User avatar
DerikB
High Range 4WD
High Range 4WD
Posts: 61
Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2018 Hilux 2.8 XtraCab 4x4 Auto
Real Name: Derik
Club VHF Licence: HC143

Re: Vigo DIY Frontrunner Roofrack Installation

Post by DerikB »

coetzer94 wrote:Ek weet die is n ou draad, maar hoe het daardie rivnuts gehou in die kalahari? Ek wil ook n Roof rack op die trokkie sit maar eks bekommerd oor rivnuts, veral as ek gereeld die rak wil afhaal en terug sit.
Jammer, ek sien nou eers jou vraag.

Ek is nog heeltemal tevrede met die Rivnuts.

Na duisende kilos sinkplaat het ek onlangs weer die rails afgehaal om daaronder skoon te maak en ek het spesifiek gekyk vir enige speling of tekens van probleme. Niks opgemerk nie.

Soos ek genoem het toe ons die installasie gedoen het, al werk wat die rak gehad het, was om my sonpaneel te dra. As ek bv. n daktent daarop wou sit, sou ek tien teen nie die rivnuts gebruik het nie.
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
Image
ORRA VHF Call Sign: B78
User avatar
coetzer94
Low Range 4WD
Low Range 4WD
Posts: 228
Joined: Tue Nov 18, 2014 9:13 pm
Town: Pretoorsdorp
Vehicle: Silver Hilux DC 2.8 GD-6 2016
Real Name: Vian

Re: Vigo DIY Frontrunner Roofrack Installation

Post by coetzer94 »

DerikB wrote: Thu Aug 17, 2017 12:00 am
coetzer94 wrote:Ek weet die is n ou draad, maar hoe het daardie rivnuts gehou in die kalahari? Ek wil ook n Roof rack op die trokkie sit maar eks bekommerd oor rivnuts, veral as ek gereeld die rak wil afhaal en terug sit.
Jammer, ek sien nou eers jou vraag.

Ek is nog heeltemal tevrede met die Rivnuts.

Na duisende kilos sinkplaat het ek onlangs weer die rails afgehaal om daaronder skoon te maak en ek het spesifiek gekyk vir enige speling of tekens van probleme. Niks opgemerk nie.

Soos ek genoem het toe ons die installasie gedoen het, al werk wat die rak gehad het, was om my sonpaneel te dra. As ek bv. n daktent daarop wou sit, sou ek tien teen nie die rivnuts gebruik het nie.
Dankie Derik

Eks bly om te hoor dit gaan so glad. Kyk die idee is glad nie om swaar goed te laai nie, ek wil ook n sonpaneel en stoele en daai tipe van goed opsit. Al wat ek wil opsit wat effe swaar is sal die highlift wees. Wat is jou gevoel?

Ek kyk ook na die african outback loadbar mounting system soos in die vorige post genoem. Die idee daarvan is n 100mm x 20mm x 10mm?? blokkie wat binne in die "gutter" van die bakkie pas. Die blok word dan vasgesit met boute deur die dak. Dit word dan in n (4mm) plaat wat getap is om die boute te aanvaar ingedraai om die vas te maak. ek dink die sisteem sal dalk bietjie sterker as rivnuts wees, maar dan gaan ek ook die headliner moet laatsak om vas te maak.....en daarna sien ek bietjie op.

Iemand wat al die headliner laat sak het om tips te gee??
--------------------------------------------------------------------------------------------------------------------------------

Working on my bucket list only makes it longer
Post Reply

Return to “Build your own:”