The main way to increase the cargo capacity of a car is to install a roof rack. The trunk allows you to place much more luggage than is provided for by the standard design of the passenger car, in addition, it becomes available to transport things that exceed the dimensions of the car's interior (pipes, boards, siding and other building materials). Auto shops offer a huge range of luggage designs for both a specific model and universal options. However, all factory trunks are characterized by a considerable cost, which not all motorists can afford to pay. An alternative solution could be to make a roof rack on the roof of the car with your own hands.

Choosing a trunk design

First of all, you should measure the linear dimensions of the roof of the car in order to determine the possible dimensions of the trunk. It should not extend beyond the roof of the car in the windshield area, and should not create obstacles for opening the rear door. especially if it opens up (or the trunk lid).

To be sure, you can adhere to the dimensions of the factory trunks designed for cars of the corresponding model - such information is available on the manufacturers' websites. In the end, you can arrange with a neighbor in the parking lot or a colleague at work to take measurements and photograph the design of his trunk.

Next, you should decide on the type of luggage you need. For the transportation of goods of various shapes, a trunk in the form of a basket with sides is suitable. If the main type of luggage is long items (roll materials, ladders, etc.), then a flat open platform should be preferred.

You also need to decide on the number of fasteners:

for sedans and hatchbacks, four points of support will be enough;
for cars with a roof length of more than 2.5 meters, it is worth increasing the number of mounts to six.

The result of this stage should be a schematic diagram of the design, made in the form of a drawing of the luggage device, indicating the linear dimensions.

Choosing the material for the trunk

The most common material for making a do-it-yourself roof rack for a car is a metal profile. The best option is an aluminum alloy profile. It is easy to cut and bend to the desired shape, and aluminum is not subject to corrosion and has a low specific gravity.

For a base that has a significant load, you can use a steel rectangular profile with a section of 20x30 mm and a wall thickness of 2 mm. The use of round pipes is less preferable as they can cause the load to slip during transport.

Note! The trunk made of steel will have a large weight, which will ultimately reduce the payload of the transported cargo.

Using a grinder, the profile is cut into elements according to the selected drawing. The rectangular base is welded by electric welding and reinforced with longitudinal struts. To ensure rigidity, the struts are connected by transverse bridges, forming a slatted bottom of the trunk. Further, vertical racks of the required height are made, which are connected to the base with screws. From above, longitudinal and transverse crossbars are welded to the racks, completing the spatial structure of the trunk. Mounts suitable for the corresponding car model are installed at the bottom of the structure.

An example of making a trunk from a metal profile can be seen in the following video:

When choosing metal rolling, preference should be given to stainless steels or consider ways to protect the finished product from corrosion (for example, painting with zinc-containing compounds).

These options are suitable for those who have the ability and skills to use welding equipment. If you cook the trunk according to a unique project from an unfamiliar welder for money, then the total cost of the work may exceed the price of a factory product. Therefore, many motorists use such a not-quite-functional option as lumber to make a trunk.

In principle, the wooden structure successfully copes with the periodic transportation of light loads that cannot be fixed on the standard car rails.

Important! Remember that every 50 kilograms of cargo on the roof increases the height of the car's center of gravity by 10%, which negatively affects the car's handling.

Another source material option is impact-resistant ABS plastic. Craftsmen with extensive experience in creating fiberglass body kits for cars make roof rails, platforms and even airboxes from polymer compositions, which can successfully compete with branded models in terms of quality and reliability. However, for most motorists, this method of increasing the luggage capacity of a car with their own hands is exotic and almost impossible.

Decide on the type of fasteners

The method of fixing the trunk depends on the design of the roof of the car and on the type of seats for installing the luggage system.

On classic cars such as VAZ 2105-21099 and old foreign cars with longitudinal gutters on the roof to install the trunk, it is necessary to make or select fasteners in the form of a metal stop with a fixing clip on a screw connection. A continuous drain strip allows you to install fasteners at an arbitrary distance from each other, which makes it possible to use luggage systems of various dimensions and carrying capacity.

For machines equipped with longitudinal railings, a different modification of the U-profile clamping fixtures is required. Such mounts for a car roof rack can be made with your own hands from a metal sheet, bent to the shape of the rails and attached to the trunk structure with screws. Often used as a ready-made clamp muffler clamps or construction analogs. The clamp wraps around the railing with a semicircular part, the open ends of the fastening are threaded into pre-drilled holes in the transverse struts of the luggage platform and are attracted by nuts.

To ensure the necessary tightness of the fit of such a mount, it is recommended that sealing gaskets of a suitable shape be cut out of rubber or soft plastic.

Some modern cars have regular places for installing roof rails or trunks. The cargo box is fixed with special transverse screws, which are usually hidden under protective plugs. Unfortunately, for such a design of landing nests, it is very difficult to make fasteners with your own hands. Owners of such cars have to look for used roof rails or broken airboxes of a compatible design that can serve as a donor of mounts for a makeshift roof rack.

Car owners who are going to actively exploit a home-made luggage structure should not forget a few important rules:

for a loaded car, a calm driving style is preferable, without sudden changes in speed, turns and lane changes;
any load must be carefully secured with ropes, tie-down straps or locking devices;
it is imperative to check the integrity of the structure and the reliability of the fastenings of the trunk before transporting the cargo and after unloading.

Roof rails are a device on the roof of the car, which gives it a unique appearance and improves its technical characteristics. Such accessories are used for mounting additional luggage equipment. It can be:

specialized box;
basket on the roof of the car;
mounts for bicycles, skis, snowboards, as well as other tourist equipment for recreation.

But before mounting the trunk, boxing, or specialized mounts, it is necessary to install additional cross members. They will be securely attached to the rails, and to them, respectively, the equipment being transported. These crossbars for the trunk can be either purchased at specialized car dealerships or made independently. Next, we describe several ways to make crossbars for roof rails with your own hands.

Tools and materials for the manufacture of roof crossbars

Do-it-yourself crossbars for roof rails will not be difficult. For their manufacture, it is necessary to take into account the characteristics of each car, as well as the individual wishes of the motorist. The main "plus" of creating fasteners with your own hands is the price, since the purchased crossbars will cost several times more.

Also, do not forget about the characteristics of strength. When transporting cargo, the main thing is that it does not fall and does not create an emergency. Therefore, it is also not worth saving on the quality of materials for the manufacture of cross members for the trunk. Today, the load carried on the roof of a car can range from 60 to 110 kg.

To create crossbars for roof rails, we need:

metallic profile;
grinder, drill, welding;
fixing material (bolts, nuts, washers);
mounting foam;
heat shrink;
building hair dryer;
paint, brush.

Typically, the roof bars for installing the trunk are two parallel straight lines, which are fixed on the roof rails. During their manufacture, it is necessary to take into account the shape of the roof, as well as its width. The material for them can be a metal profile made of light-alloy materials, or a square pipe (metal thickness - up to 3 mm).

Cargo strap

The cargo is secured by:

belt fasteners (if the cargo is transported directly on the crossbars);
grids (if a basket is used);
supporting or clamping clamps (for transporting skis, snowboards, bicycles).

Also, during the installation and removal of the crossbars, it is necessary to provide rubberized gaskets to prevent damage to the paintwork of the car body. Below we consider several options for creating crossbars with your own hands.

Options for homemade roof crossbars

Option number 1. This creation of crossbars will be the simplest and will not take much time. In this case, we will need:

Manufacturing process:

Option number 2. This option will not be as practical as the first, and will require breaking the integrity of the car's roof rails. So, we need:

The process of making crossbars with your own hands will be as follows:

This process of fabricating and installing cross members is recommended for permanent use. After dismantling the crossbars, the appearance of the car deteriorates greatly due to the drilled roof rails.

Option number 3. This option will be more practical, since the materials used in it have a more streamlined shape. Therefore, when the car is moving, almost no noise is created. But the maximum load capacity of these crossbars does not exceed 60 kg. By slightly strengthening the method presented below, it will be possible to load up to 90 kg. But this will require additional costs. For the manufacture of crossbars we need:

The process of making crossbars for roof rails will be quite simple. The main thing is to take the right measurements and not make a mistake:

This process of making crossbars is quite simple and does not require any special skills. Also, the advantages of these crossbars for installing the trunk are that they can be installed at different distances, depending on the cargo being transported and the brand of the car.

Option number 4. In this case, it is necessary that the car rails have specially designed mounting holes. For the manufacture of crossbars for the trunk, we need experience in welding. We list the materials needed to create the crossbars.

Reading 4 min.

Quite often, car owners are faced with a problem when there is not enough space in the cabin to carry large or oversized cargo. In this case, you need additional space where you can put various things, luggage, etc. Today, the market offers a lot of luggage racks that allow you to place a large amount of cargo on the roof of the car. However, there is one significant drawback - the cost, which not all drivers can afford. The way out of the situation can be a do-it-yourself car roof rack, which is done quite simply. All that is required of you is to purchase materials, acquire the necessary tools and start working. Such a device has many advantages:

Creation of an additional place for the transportation of the necessary cargo.
Protection of the roof of the car from damage.
Basis for installing additional equipment (antenna, lights, etc.).

Moreover, for off-road lovers, a car roof rack is indispensable. It allows you to fix and transport various equipment (shovels, etc.). At the same time, it is impossible not to note the disadvantages of such a design. First of all, aerodynamics suffer from the installation of the trunk, which is the reason for an increase in fuel consumption by 1-2 liters. In some cases, calculation errors can cause increased controllability and the appearance of extraneous noise.

Materials used

Depending on the climate and conditions of use, it is necessary to choose the material for the manufacture of the trunk. Metal is considered the most suitable option. The main condition when choosing a material is the minimum weight, but at the same time it must be quite strong. If the structure is too heavy, then this will create a serious load on the roof of the car. Preference should be given to the following options:

Aluminum.
Stainless steel.
profile pipe.

Aluminum is perfect for a roof rack, and for several reasons. Its main advantage is that it is lightweight. In addition, it does not rust and is resistant to corrosion. Finally, it is very easy to work with and can be formed into any shape that fits your car.

If the price of aluminum does not suit you, or for another reason you do not want to choose this material, then a profile pipe can become an alternative. As a rule, such a trunk is placed on domestic cars (SUVs such as Niva, Patriot, etc.). Finally, stainless steel is the most affordable option. The advantage of this material is that the steel is very flexible and strong. But there is also a minus - the weight of such a design will be much more than that of a trunk made of aluminum or a profile tube.

Manufacturing procedure

Regardless of the material chosen, making a roof rack for your car can be quite simple and fast. All stages, as a rule, are standard and include the following actions:

Calculating dimensions and creating a layout.
Creation of the frame and its strengthening.
Installation of load-bearing panels and work on the appearance.
Creation of boards.
Installation of the structure on the trunk.

Let's take a closer look at each of the stages. First you need to measure the width and length of the roof, then draw a sketch and calculate the amount of material needed and its weight. Welding of the structure must begin from the outer perimeter, and then fix the load-bearing strips. A prerequisite is the reinforcement of the luggage compartment with longitudinal crosspieces.

Move on. The resulting frame must be securely strengthened and fixed using a profile pipe or metal plates. This will give the trunk for the car reliability and integrity. In addition, it is necessary to pay attention to the appearance of the structure and make it attractive, suitable for the overall style. To do this, you can install a special arc from the profile, which will improve aerodynamics and streamlining. The installation of the arc must be carried out in the front, bending the edges and fixing by welding. By the way, it is also desirable to fix the jumpers to the arc.

After the arc is installed, you need to add the sides. The roof rack is ready and now you can start installing it. It is advisable to treat the structure with primer and paint, which will increase its durability and resistance to external influences.

That's all, if you have the time and desire to save money on buying a trunk, then such a project is quite feasible with your own hands. Do everything step by step and reliably, following the main recommendations. In this case, the structure will turn out to be strong and will be folded for many years.

Passenger cars, crossovers and jeeps are not always equipped with a capacious trunk. Drivers put a jack in it, take a tow rope with them. It fits a spare wheel, a set of tools. 60% of the trunk space remains for storing personal items.

What if you want to carry more luggage? Install a roof rack, so you expand the capabilities of the car, take the mower, boxes, boxes to the dacha.

How much does a new trunk cost, is it possible to save money?

Automakers offer buyers trunks for cars of their own production, but branded products are expensive. Do you want to save? Then assemble the structure yourself and install it on the rails. The more parts and materials you have in your garage, the cheaper the job will be.

There are several advantages to making your own trunk:

The first advantage is that you will make the design according to the given dimensions, choose the most suitable shape. This is an important point, given the aerodynamic properties of the machine. There are many models of trunks, you can easily find the right one.
The second advantage: you will save money, because cheap materials that are in the garage are suitable for making the trunk. And automakers, releasing products, use modern technologies.
The third advantage: the compatibility of the trunk and the car. You will create a design, taking into account the desired characteristics. Carrying capacity, volume and useful area of the trunk will be what you need.

Installing a roof rack on a car (+ video)

By purchasing a factory trunk, you will receive installation instructions and fasteners in the kit. And what to do with a homemade trunk? See if the machine is equipped with slatted or longitudinal outer beams. If they are, then installing the trunk is easy. In addition, with the help of special belts it is possible to fasten a wardrobe trunk or cargo to the guides, and transport things.

Have you decided to make the trunk yourself? You don’t need any special equipment to work, you just need to buy fasteners.

Main design requirements

A homemade trunk must comply with the standards. Be sure to take into account the geometric dimensions, do not make the trunk with edges protruding beyond the roof of the car. This design will change the position of the center of gravity of the car, reduce stability.

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Pay attention to the strength of a homemade trunk. Even using metal structures for production, do not load the structure. The weight of the load carried on the trunk must not exceed 120 kg. Do not exceed this value, otherwise the car body will be deformed. The power of the car and the speed will also decrease, the safety of the car will decrease.

How to make a do-it-yourself trunk mount on roof rails

If the rails are not installed on the machine, then mount them yourself. Buy two sets of sidewalls at the auto shop. Each set comes with two sidewalls, you need four.

Buy a metal profiled pipe. Choose not a round, but a rectangular profile, so the load will be stable. The wall thickness should not be less than 2 mm, the best section is 15 × 15 mm. For work, you will need a welding machine and consumables. Buy a net, a tape measure. Now you can start work.

Determine the size of the structure. Measure the car roof length and width. Given these indicators, determine the geometric dimensions of the trunk. Then cut the profiled pipe into several pieces. So you get longitudinal and transverse guides.

At the auto shop, buy cross bars for roof rails. If you can’t find railings of the desired length on sale, buy those that are on sale. Then cut and install on the machine. Two sets are enough to spread the weight over eight support points.

A correctly installed frame made of profiled pipe repeats the perimeter of the roof of the car. Take the welding machine and attach the cross members to the structure. So you will make the bottom base of the trunk, do the same for the top. You can not weld parts of the trunk, but make removable jumpers.

Weld the two parts of the trunk, immediately clean the seams. Attach the cross members to the body using bolts and nuts. Fasten the roof rack to the car, put polyurethane gaskets in the attachment points. On sale there are plastic and rubber products. This will protect the body of the car from damage.

Lay a grid in the lower part of the structure, 4 × 4 cm cells are enough. If you buy a grid with small cells, then snow will begin to accumulate in them in winter, and fallen leaves will gather in a fine grid in autumn.

Fix the trunk and paint, this will increase the life of the structure. The painted trunk will look aesthetically pleasing. Install reflectors or a fog lamp, connect it to the on-board network.

Outcome

Assembling the trunk is easy, you will do the job in two days. A homemade roof rack on rails is suitable for transporting things on tourist trips. It is indispensable for the delivery of goods to the country. On the trunk you will take a bicycle to the dacha, in winter you can transport skis on it. Summer residents will bring building materials to the site. All things will be safe.

If you have not yet decided whether to make a trunk, weigh the pros and cons, then make a decision. This is a useful design, and it is quite simple to make it.