Defender specific Cross Bar Design

Tiktaalik

Founding Member
Hello everyone.

This idea started when I purchased my Mercedes 300GD in June of 2017. I was trying to fit my Front Runner rack onto the rare safari (double) roof. I started out by sketching rack feet designs that would clear the safari roof without interference. The rack foot design turned into a new cross bar design which I am currently in the first stages of prototyping and as it turns out this will be a perfect fit for a (classic) Land Rover Defender as well!

Boxy cars should have boxy racks (and boxy cross bars)! Thats pretty much the design philosophy behind this. Mainly I just wanted to utilize the flat sides for mounting stuff. I have a Hannibal awning that I've designed new mounts for which integrates with this cross bar design. The final product will be made from hard coat (type 3) anodized aluminum and it should fit all G wagens and all Land Rover Defender (classics) once its complete.


Cross Bar Design 010520.22.jpg
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MountainD

Technical Excellence Contributor
The pinching and loading of the rails contributes to leaking and separation of the roofs flawed design—at least that is my impression and I’ve known others that feel this way... I’d love to see a more distributed foot. Have you seen this separation exacerbated from footed racks before?
 
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RBBailey

NAS-ROW Addict
Callsign: KF7KFZ
I would say the wider foot is very important. Even with my Thule racks, I can tell they want to lean back and forth.

Also, I do like a leaned-in look. That is, angled in toward the middle of the vehicle. I've never much liked the straight up and down racks, unless they are galvanized, and on a Series vehicle.
 

Tiktaalik

Founding Member
Are you referring to the gutter rails? Never had any issues with that in my Defender other than the cracking of paint due to the spongy soft foam at the bottom of the gutter.

The pinching and loading of the rails contributes to leaking and separation of the roofs flawed design—at least that is my impression and I’ve known others that feel this way... I’d love to see a more distributed foot. Have you seen this separation exacerbated from footed racks before?
 

Tiktaalik

Founding Member
Never had any issues with the three Front Runner Racks that I have owned throughout the years. Similar foot design and I've used them as cross bars as well. No issue with back and forth movement because I had stuff mounted to them.

Plenty of other options out there for the-leaned in look. The whole point of this design was to create a flat side that allows you to mount awnings, traction mats, etc. I'm re-designing the mounts for a Hannibal Awning that I bought that will integrate into the flat sides of this rack design.

I might widen the gutter blades a bit to increase stability, similar to the Big Country racks.

I would say the wider foot is very important. Even with my Thule racks, I can tell they want to lean back and forth.

Also, I do like a leaned-in look. That is, angled in toward the middle of the vehicle. I've never much liked the straight up and down racks, unless they are galvanized, and on a Series vehicle.
 

RBBailey

NAS-ROW Addict
Callsign: KF7KFZ
Plenty of other options out there for the-leaned in look. The whole point of this design was to create a flat side that allows you to mount awnings, traction mats, etc.
Ah, yes, that makes sense. Not my style for my truck, but I see what you are going for.
 

Red90

Well-known member
Also, I do like a leaned-in look. That is, angled in toward the middle of the vehicle. I've never much liked the straight up and down racks, unless they are galvanized, and on a Series vehicle.
The same angle as the sides would look best, IMO.
 

rocky

Well-known member
That damage looks familiar. Did that to my D1.
My D1 had the Thule high foot mounts, which work well with Series and defenders even with external roof braces.
 

Tiktaalik

Founding Member
There’s a simple solution to prevent that from happening. On my last set up I put a small aluminum U-Channel inside the rain gutter in order to disperse the load pressure. The channel ran the entire length of the rain gutter and the rack feet would sit inside the channel thus dispersing the load pressure.

Bars tend to catch on passing bits of tree and this happens as they get pulled off :-
View attachment 11302
 

Tiktaalik

Founding Member
Hi Everyone.

Click this link if you are interested in receiving emails regarding the development progress of this roof rack design: http://eepurl.com/g1UIl9

Those of you who sign up will receive progress updates and pricing information (when it becomes available). I may also send out an occasional survey to learn more about your needs and preferences as it relates to roof racks.

Thanks!
 

Tiktaalik

Founding Member
Thanks!

I like the boxy design too! Makes it easier to mount awnings, traction mats and other accessories to the sides.

I wish I could say I will make a NAS version but I have so many other things further up on my priority list. I’m not sure it’s worth the investment (time primarily) if only a few people want it. If there is sufficient demand for it, I’ll consider it.

I really like the look of boxy design, will you make one for NAS 90 as well ? Thanks.
 
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