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Excursion - King of SUVs 2000 - 2005 Ford Excursion

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  #16  
Old 12-09-2011, 05:33 PM
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Got a little more done before I ran out of shielding gas for the welder. I hope you guys like it so far. Any comments or suggestions are welcome.

2011-12-06 11.40.11
More grinding off the galvanizing and some fish mouthing to make a better fit.

2011-12-06 13.02.48
Laying out the bars the length of the rack.

2011-12-06 14.54.35
Finish welding on the supports that run across the roof. I used 2 layers for the floor of the safari rack. One frame on the bottom with bars across the width of the roof and a second frame with bars running the length of the roof. It is probably more than I needed for support but I would rather have it overbuilt the fail while running down the road.

2011-12-06 14.54.44

2011-12-06 14.55.03
Laid out of the roof to check the looks and placement. I was freaking out tht it was too big, until I put it on the roof and was reminded how big the Excursion was again.

2011-12-06 15-1.52.29
I put the 2 layers together and started tacking everything into place. I had to tack everywhere the bars crossed to keep things from moving or rattling.

2011-12-07 12.05.04
Laying out the upper rail. Trying to make sure it is square without any helpers sucked. I had to use the magnets, clamps, and straps to keep it square and get it tacked into place.

2011-12-09 15.28.28
All of the supports tacked into place just waiting to be fully welded.

I do have a trick or two left, but that will have to wait for a gas refill and a little more time. Hope I get it all done before our trip in 8 days.
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  #17  
Old 12-09-2011, 06:30 PM
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Quote:
Originally Posted by bigzirb View Post
Anyone with suggestions of the best way to prep and paint the combination of the galvanized and the welded stuff when I'm done with the welding this weekend? I don't want it to flake off and have to be repainting or touching it up all the time, and I don't want it to rust through the paint. Thanks in advance.
You can use good old white vinegar to etch the galvanized and then use a metal primer and paint of your choice. After your grinding, just wipe down the rack with vinegar on a towel to remove the impurities/oils and move on to the primer/paint stage. Using vinegar is a nice inexpensive way to give the primer something to stick to when shooting galvanized.
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Old 12-09-2011, 06:34 PM
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Great tip there Housedad on removing the galvanizing with acid, I have done that in the past as well. This also works if you need to solder some galvanized together as well, say for a metal pan or something.
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  #19  
Old 12-11-2011, 04:22 PM
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Safari Rack work

Ok, I finally got the welder tuned back up and started striping the galvanizing to throw some paint down. I figured you guys would like some more pics.

2011-12-11 14.35.51
A little paint.

2011-12-11 14.36.02

2011-12-11 15.44.34
A teaser of the next addition.

2011-12-11 15.44.28

I have to get this all done and mounted by Thursday so I'll post the rest later, got to get back to work now.
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  #20  
Old 12-11-2011, 07:50 PM
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Big, very nice work!

Keep the pics coming!
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  #21  
Old 12-11-2011, 07:56 PM
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Looks great man. Keep up the good work. Cant wait to see it mounted. You can probably make a small fortune selling these. What are the small pieces? Keep us posted please. Reps to you.
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  #22  
Old 12-12-2011, 08:08 AM
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Big, can you post the measurements... Also how are you mounting it?

Thanks
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  #23  
Old 12-12-2011, 11:59 AM
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What does this rack weigh? The "stock" roof rack is limited to 200 pounds. I assume that is due to the limits of the cross bars & not the side rails.

Since this one still rests on the "stck" side rails, what sort of weight do you think will be a "reasonable" load?

Powder Coating would have been a possible alternative to paint....

D
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  #24  
Old 12-12-2011, 02:03 PM
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hekk i would be interested in buying this kind of roof rack! that looks nice
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  #25  
Old 12-14-2011, 04:51 PM
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Big, tomorrow is Thursday, are you close to completing the rack install?
Post some pics.
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  #26  
Old 12-14-2011, 07:57 PM
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Put me down for one. How would you mount the spare tire to it?
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  #27  
Old 12-14-2011, 08:41 PM
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I wish I had a welding machine, That looks fun.
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  #28  
Old 12-15-2011, 12:28 AM
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Quote:
Originally Posted by LivingLarge View Post
Big, tomorrow is Thursday, are you close to completing the rack install?
Post some pics.
It is on, just need some more hardware to completely secure it. As usual I had to modify the plan as things never seem to work out as well as you want them to. Here is a teaser before I call it a night. I will post the final details tomorrow (later today I guess).

2011-12-14 17.07.55
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  #29  
Old 12-15-2011, 08:47 AM
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marvin corty
Fantastic!

A lot of us have been waiting and watching. It looks really good, I know you are proud of it.

Looking forward to more pics and an 'after the trip' update on how it worked out.
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  #30  
Old 12-15-2011, 01:33 PM
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Ok the rack is done, mounted, and already has 2 tires strapped to it. I'm amazed at how many times I have had to modify the plan but happy with the result, so far...

I'll see if I can wrap up the construction and installation process for you guys, I missed pics of a few things but you should get the idea.

I had planned to bolt the rack to the stock cross bars, possibly adding 2 more cross bars to distribute the load better. Plan changed because I can't find an Ex in a salvage yard anywhere around here to get the cross bars, I didn't like how high it was, and I didn't want to rely on the factory clamps to hold it all down. So off came the cross bars and side rails for some more cutting of the rubber spacer and drilling of some holes in the rails.
2011-12-14 14.26.26

2011-12-15 11.05.59
Decided to use the J-bolts to attach the rack to the side rails. They have a safe working load of #160 each and I used 10 to attach the rack to the rail with fender washers and nylock nuts so they don't work loose.

2011-12-15 10.48.29
Shot of how far off the roof the rack is sitting.

2011-12-15 11.01.59

2011-12-15 11.01.54

3 pieces of 3/8 rubber stacked to support the rack. The bottom on is longer to spread the load on the rail and the top 2 are what was cut from under the rail to get the spacing right for the J-bolts.

2011-12-15 11.01.34
The J-bolts on the driver side.

2011-12-15 11.49.46
2011-12-15 11.50.10
You wanted to see what the little pieces were for so here it is. I wanted a wind deflector but wanted to be able to remove it if needed. The sides are open so it doesn't contribute to the side sail area of the Ex.
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Old 12-15-2011, 01:33 PM
 
 
 
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