Dogfish
10-30-2010, 12:30 PM
This is something I did about 8 years ago. It has held up well and has been on two vans. It is all aluminum and vinyl... won't rust and is probably stronger than the original.
First gather the basic materials and tools. A hack saw, tape measure and a hammer should suffice. You may want to use a pair of channel locks to remove the old one if you are lucky enough to have one. The old one will help as a guide... even if it is in multiple pieces.
Basic Materials:90
Right, the basic material is an old lawn chair. Heavy aluminum tube and vinyl webbing. You've all seen them out at the trash... next time pick one up.
91
You want to salvage the seat and back part from the arms and legs. This is what you will be working with. It may be a little difficult to break at the welds. Try a sawzall or hammer and chisel if needed. I lucked out... the chair was already broken at the welds.
Measure an overall length from the retainer bolt to a point where the rack will need to be bent up to reach the mounts. Add the distance needed to reach the mounts... leave it long if you like... you can fine tune it later.
92
To make the bends, gently flatten the tube with hammer. Also flatten the point where the retainer bolt will grab the rack.
Bend the cut ends of the tubes up to reach the mounts... mark and drill the appropriate holes, and cut any extra that is past the holes.
93
Black paint is optional... and will add some time to the build.
I plan on making another and I will include all the dimensions and step by step photos.
Give it a try... the aluminum is easy to work with and the only investment is your time.
-Jim
First gather the basic materials and tools. A hack saw, tape measure and a hammer should suffice. You may want to use a pair of channel locks to remove the old one if you are lucky enough to have one. The old one will help as a guide... even if it is in multiple pieces.
Basic Materials:90
Right, the basic material is an old lawn chair. Heavy aluminum tube and vinyl webbing. You've all seen them out at the trash... next time pick one up.
91
You want to salvage the seat and back part from the arms and legs. This is what you will be working with. It may be a little difficult to break at the welds. Try a sawzall or hammer and chisel if needed. I lucked out... the chair was already broken at the welds.
Measure an overall length from the retainer bolt to a point where the rack will need to be bent up to reach the mounts. Add the distance needed to reach the mounts... leave it long if you like... you can fine tune it later.
92
To make the bends, gently flatten the tube with hammer. Also flatten the point where the retainer bolt will grab the rack.
Bend the cut ends of the tubes up to reach the mounts... mark and drill the appropriate holes, and cut any extra that is past the holes.
93
Black paint is optional... and will add some time to the build.
I plan on making another and I will include all the dimensions and step by step photos.
Give it a try... the aluminum is easy to work with and the only investment is your time.
-Jim