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my DIY luggage rack

MangoSmoothie.caMangoSmoothie.ca
so i have a 'mini' few projects on the go right now (extra engine, vert frame and this). depending on how motivated / frustrated i am feeling, i'll pick when i have garage time. lately i've been building the extra motor - because, well it makes no sense as mine is fine. i should be focusing on the vert frame - but i digress




I've had this 1/2 built for a hundred months, so i decided to start to finish it off.

* i started at Rona (Canadian version of home depot) and went to the electrical section. bought two 10 sections of 1/2 steel conduit.

* made a cardboard template copy of the shape of my decklid.


* bent the conduit with a conduit bender - VERY carefully to not crimp it






* welded it together


* stop for 100 months (probably 3/4 year)


* bought 3/8" threaded rod and nylock nuts, some flat steel

* placed it on the car - balancing it on a bunch of towels for the right height - used 1/4" masking tape to get the proper hole placement between the deck vent



* took it off * fabbed up some cross bracing

* welded it on

here is where it is right now:




my welds are not great - actually pretty shitty - but i plan to grind them smooth - coat with a bit of filler and paint silver to match my wheels

next up: another trip to Rona / Home Depot for cedar wood. i have the stain already and it's pretty nice. i need to weld on tabs - fab up some sleeves for the threaded rod (so you can't see them) and then finish it off.

the weather is turning now, so i am a little more motivated to get her ready.

BTW - i probably have $23 into this ($3 alone for the plated nylocks)

hope you enjoy! :)


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MangoSmoothie.caMangoSmoothie.ca
so i have a 'mini' few projects on the go right now (extra engine, vert frame and this). depending on how motivated / frustrated i am feeling, i'll pick when i have garage time. lately i've been building the extra motor - because, well it makes no sense as mine is fine. i should be focusing on the vert frame - but i digress




I've had this 1/2 built for a hundred months, so i decided to start to finish it off.

* i started at Rona (Canadian version of home depot) and went to the electrical section. bought two 10 sections of 1/2 steel conduit.

* made a cardboard template copy of the shape of my decklid.


* bent the conduit with a conduit bender - VERY carefully to not crimp it






* welded it together


* stop for 100 months (probably 3/4 year)


* bought 3/8" threaded rod and nylock nuts, some flat steel

* placed it on the car - balancing it on a bunch of towels for the right height - used 1/4" masking tape to get the proper hole placement between the deck vent



* took it off * fabbed up some cross bracing

* welded it on

here is where it is right now:




my welds are not great - actually pretty shitty - but i plan to grind them smooth - coat with a bit of filler and paint silver to match my wheels

next up: another trip to Rona / Home Depot for cedar wood. i have the stain already and it's pretty nice. i need to weld on tabs - fab up some sleeves for the threaded rod (so you can't see them) and then finish it off.

the weather is turning now, so i am a little more motivated to get her ready.

BTW - i probably have $23 into this ($3 alone for the plated nylocks)

hope you enjoy! :)


MangoSmoothie.caMangoSmoothie.ca
Troy - right now, they are all the same length threaded studs with nuts in place so i can fine-tune the height. the top studs stick through a lot more than the bottom ones. i'm going to cut them down once i finish things off.

as with the car - i wanted it low. i really like many features on the VS rack, but it sits too high, so i understand what you are talking about.

MangoSmoothie.caMangoSmoothie.ca
fair enough - i agree in principal.

i've lowered mine quite a bit from a VS rack (~1.25" off the decklid all around) and i'm willing to put money on the table that i see no increase in my operating temperature.

i remember folks said airflow would be compromised when i put my rubber seal around the engine compartment opening. i saw no difference in operating temp - in fact, aside from the aesthetics, it reduced the vibrations.
MangoSmoothie.caMangoSmoothie.ca
i picked up the wood and stainless hardware last night.

i measured and cut some to fit. i think it will look pretty sharp (sorry no pics)

next up is welding on mounting tabs and smoothing out my crap-tacular welds with a flap disc.

Then it's off to finishing cutting the wood, staining it and painting the rack.

i didn't go with cedar. i looked at it, but the grain was better in the other kind of wood i bought (fir i think)
MangoSmoothie.caMangoSmoothie.ca
i decided to shave the fur and countersink the stainless hardware on the bottom side so you won't see my $8 screws.

finished up the tabs - welded them on - getting close now.

i just need to pick up a few flapper wheels to smooth those awesome welds.

yes, i am welding on a plastic recycling box.

yes, i smelled plastic.

yes, the garage smoke alarm went off.

and no, my daughter didn't wake up or did i start a fire. it's all good.









MangoSmoothie.caMangoSmoothie.ca
slats are now cut. i screwed up one (laying across the top

i need to route them and grind the welds (picked up some cool dual layer flappers (60 grit and 120 grit)

the remaining stuff is noisy and the garage is pretty close to my little girls bedroom (who is sleeping when i am in the garage....

hmmm...

i'll try to snag an hour of garage time this weekend and see where i get.

(it's Douglas fir BTW)

MangoSmoothie.caMangoSmoothie.ca
thanks guys - this has been a pretty fun little project.

i got the cut off wheel and flapper out this weekend. cut down some of the spot welds for the mounting tabs and smoothed out the whole thing. man - it is 200% better.

i then slapped on a generous coat of fiberglass filler - smoothed that out with the 80/120 sandpaper in a 1/4 sheet sander. i did the bends by hand.

then, just now put on the final coat of filler.

it actually turned out nicer than i was expecting.

i'm going to high-build primer it after a final going over of 150 grit

MangoSmoothie.caMangoSmoothie.ca
ha ha. not exactly sure how to reply to that.

i picked up some custom mixed paint tonight. it's called 'bright silver'. i'll snap a picture of the mixture. it has white and blue in it to make it 'brighter' apparently.

it's very nice compromise to a full chrome rack (which i could do cause of my awesome welding skills needing to be covered up with filler)

i'm gunna get some garage time tonight, so i'll hopefully get it coated

oh ya - i have to drill / countersink screw holes first (i'm remembering as i type)
MangoSmoothie.caMangoSmoothie.ca
no - sorry. they take too long. this one has been done in 1/2 hr to 45 minute increments over many months (although i have momentum from you guys on this last half of the project)

seriously - anyone can do this stuff. isn't not hard, or expensive, just need time and a little know-how (hopefully i help out a little here). for example: i had no idea how to weld 3 years ago (not like you could tell i have 3 yrs exp. from those welds mind you). just do some research, pick up some tool and try it. this was my second attempt at the rack due to the crazy curves needed to hug the body

i slapped on some high build primer tonight. i am not going to top coat paint it tonight. there are a few minor areas that i need to touch up (fill) and re-sand/prime.

anywho - here is a picture cause we're all men who like pictures. :)


FM Former Member
Yup. Just some conduit and driftwood, thirty minutes at a whack ... Presto!

No, Mango. You're an excellent craftsman, and your work is brilliant. It's not just some skill anyone can pick up; it also involves the vision needed to see it beforehand, knowledge of what the tool is intended to do and the desire to push the limits of what you want to learn in the process.

I'd like to meet you someday, and hear how your car evolved into what it is. I very much enjoy reading and seeing what you post here. Thanks for taking the time.
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