A roof rack is a necessity for a Jeep owner. It can haul bikes, surfboards, even furniture to wherever you want to go. Jeep owners can make their own roof racks if they want to save some money and want the satisfaction of building something on your own.
Cut two 4 foot sections of steel pipe using a pipe saw (hacksaw, or metal saw will work). Then cut four 3 inch by 3 inch squares of metal plate from the 1 foot by 1 foot plate, using a metal band saw, or angle grinder with grinding bit. The metal band saw is highly recommended.
Cut two 4-inch sections of steel pipe. Cut one end of each section at a 22.5-degree angle.
Clamp one of the 4-foot sections of pipe into a vise so it is horizontally aligned. Place the square- cut end of one of the 4-inch sections of pipe against the pipe, so the square end is flush with the top of the pipe. Clamp it in place at an exact 22.5- degree angle with a C-clamp.
Trace the contour of the longer pipe with a marker onto the smaller pipe.
Clamp the smaller piece into a vise, and use an angle grinder to carefully make a curve cut. Follow the line you traced and, if necessary, line the end up with the pipe and grind more to make a flush fit.
Repeat steps 4 to 6 on the remaining 4 inch pipe sections. Place each one on the pipe, and use a level to make sure the top of the pipe section is square.
Weld one 4-inch steel pipe section to each end of the pipe, 2 inches from the end. Clamp the smaller pipe section to the longer pipe with a C-clamp. Create a quick tack weld at the top. Use a filler bar and gas welder to create a continuous bead around the seam of the two pieces. Repeat this step for each of the 4-inch pipes.
Place one steel plate onto the top of the 4-inch section of pipe. Use a carpenter's level to ensure it is level. Weld this plate to the smaller pipe using a tack weld, and then a complete weld with a filler bar.
