Vigo DIY Frontrunner Roofrack Installation

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DerikB
High Range 4WD
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Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2011 Hilux 3.0D-4D XtraCab 4x4
Real Name: Derik
Club VHF Licence: B78

Mon Nov 24, 2014 8:06 am

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:
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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.
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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.
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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.
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Then we added some silicone to the holes - For sealing and also to make it harder to rattle loose.
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We then worked towards the back following the same process for the other 2 holes.
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We replaced the factory rubber strip and drilled holes into it to match up with the riv nuts.
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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
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Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
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2013 Ford Figo TDCi
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ORRA VHF Call Sign: B78

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DerikB
High Range 4WD
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Joined: Wed Apr 17, 2013 6:08 pm
Town: Witbank
Vehicle: 2011 Hilux 3.0D-4D XtraCab 4x4
Real Name: Derik
Club VHF Licence: B78

Mon Nov 24, 2014 8:07 am

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!
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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.
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2013 Ford Figo TDCi
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MonsterLux
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Mon Nov 24, 2014 8:28 am

Neem kennis van die dak lig se draad aan die regter kant reg onnder die eerste gat van die windscreen af

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DerikB
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Vehicle: 2011 Hilux 3.0D-4D XtraCab 4x4
Real Name: Derik
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Mon Nov 24, 2014 8:37 am

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!


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Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
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2013 Ford Figo TDCi
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ORRA VHF Call Sign: B78

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Froll
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Mon Nov 24, 2014 9:59 pm

Job well done. Looks very good. :thumbup: :thumbup:

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4x4BEES
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Mon Nov 24, 2014 11:59 pm

Awesome :thumbup:

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barleigh
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Vehicle: 1995 2.4P Toyota Hilux Raider Dbl Cab - 22R
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Thu Nov 27, 2014 6:53 am

Looks great! What size panel do you have there, a 90W or bigger?

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george
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Fri Nov 28, 2014 7:45 am

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"

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DerikB
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Vehicle: 2011 Hilux 3.0D-4D XtraCab 4x4
Real Name: Derik
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Mon Dec 01, 2014 3:30 pm

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.
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2013 Ford Figo TDCi
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ORRA VHF Call Sign: B78

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DerikB
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Mon Dec 01, 2014 3:36 pm

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.
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2013 Ford Figo TDCi
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ORRA VHF Call Sign: B78

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Masekind
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Mon Dec 01, 2014 4:04 pm

Nice gedoen
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coetzer94
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Wed Jul 05, 2017 10:40 am

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?
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Henry Greeff
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Sun Aug 13, 2017 4:38 pm

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


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DerikB
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Vehicle: 2011 Hilux 3.0D-4D XtraCab 4x4
Real Name: Derik
Club VHF Licence: B78

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.
Derik

2011 Toyota Hilux 3.0 D-4D XtraCab 4x4 - ONCA Bar & Rock Sliders, Spacer Lift.
Image
2013 Ford Figo TDCi
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ORRA VHF Call Sign: B78

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coetzer94
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Wed Aug 23, 2017 8:37 am

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??
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