Manfred

Roof rails with piping rails and roof rack

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On a car there are nearly no even edges and no parallel lines. The roof rails should have a possibility to fix the awning and with additional crossbars expandable to a roof rack.
Because of the basement car parks the construction should nor bee high. This is also important for the protection of rain between the car and the awning.
With two fixed roof batten I defined the horizontal and vertical length and the angular of the girder.
The 10 girder with zinc-coat. The first in front is straight from the flat steel (20*10). The last on the rear side has a horizontal distance of 31.5 mm.
The material for the roof rails are aluminium profiles 20*20 and 20*20R made by Bosch-Rexroth. Screwing together both profiles from the down side makes it loadable. Because of the slide nuts the crossbars can be fixed on every place.
In front and behind the fixing points there are rubber blocks on the roof. The flat steels are fixed with screws.
The fixing points are not made for bending moments. Therefore the horizontal force of the awning has to underpinned on the opposite side. A fix crossbar was not possible because of the air turbulences (noise & fuel consumption). So I constructed two binders placed directly on the roof. I had enough flat steel 20*10 mm so I used it.
On the rear binder is directly on the rear edge of the roof. The piping rail for the rear tent is fixed on it.
The 20 aluminium angles supports up to 10 crossbars for the roof rack.
It is very difficult to have the holes on the construction absolute exact so it is better to drill the holes after fixing the angles.
The binders are glued with Sikaflex on the roof. On top there is a cover made of black plastic angle sections 40*10 mm. On the front side they are curved 45° by a hot air gun.
The rear binder are also covered by the black plastic angle and has additional a piping rail.
The right rear edge with the two piping rails.
The top case wit all 10 crossbars. The are fixed when they are needed because of the noise starting at 80 km/h. The profile of the crossbars are a square tube 20*15*2 mm. With this construction the maximal load for this car on the roof can be transported. It the load is not so high not every crossbar must be fixed. I will construct additional a roller on the rear side.
The finished roof rails with piping rails without the crossbars. It is always on the car. The wind noise at 130 km/h is very low.

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© by DI Manfred Gruber