Roofrack

The new parkinggarage at my work was designed for a max vehicle height of 250cm. After it was finished it turnt out to be 200cm. Actually the ceiling was 250cm, but the man who wrote the specs didn't now that there had to be cable ducting and lights mounted... So a few days before opening, the permissible heigth went to 210 cm. The day before opening The heigth went further down to 200cm.... This is a problem, the back of a 110 is 202cm.....


The first day I went testdriving with 100kg sand in the back, and a heigth at the back now at 199cm. Everything ok, but on two slopes, they mounted a cableduct just above the entrance on the upperside of the slopes. If I want to go down these two slopes, I have to drive backwards down the slope. No problem for me, but sometimes people with less inside in car specificationsgot angry...

The real problem with the heigthlimit, are the antennes on my roof. I made them for 250cm, but now I have to fold them down, every time I went in, and fold them up, when I goes out. That gives some delay, on a busy moment I get at least five people waiting behind me :( 

 

roofrack11

To make live easier, I designed a forwards foldable rack, which holds all the antennes, and some additional lights to. Designing and making was somewhat interactive. When I started building, I didn't have the complete design ready. Here are my first thought on the gutter mounts.

 

roofrack21

The first parts are the rulers and clamps for the roof. I don't have welding equipment, so everything is made with screws. The rack is made from aluminium. But is became still heavy (20KG). Also was the Alu more expensive than initial thoughts. Total meterialcosts is somewhere in the 200 euros.

 

roofrack31

First time fitting of the lower part of the rack.

 

roofrack41

Here the complete rack, before final fitting. The four circular cables are for addtional lights. The lights can be mounted on the adjusable bar just below the cables. The green box in de middle holds the relays and fuses

 

roofrack51

The green box in detail, On top is the fusebox with for every light a seperate fuse, below the fuses, are three relays. Two for the the side worklights and one for the four frontlights (not mounted jet) The two yellow lights are strobes, and there high voltage cables goes directly trough the box. The black ducting is special weather resistent tubing.

 

rackdicht1

The complete rack in driving position. The upperpart is a aluminium plate

 

rackopen1

and in fold-down position. The antenna cables are running diaganal freely over the rack. This prevent sharp bending. The antennacabels went trough the roof on left side of the vehicle, the cables for the lights go trough the roof on the right side. I use the two holes previeously drilled for the antennes, when they where directly on the roof.