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| Tom The Locksmith Member Since: 11 Sep 2014 Location: Northampton Posts: 14   
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I have a defender 110 with a whitbread roll cage 48mm thick tubing.
I'm looking for a roof rack to fit on top but I'm having trouble matching up the cage to a roof rack & can't use gutter mounts. safety devices roof racks will only clamp to 46mm tube, any ideas greatly appreciated. |
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3rd Jan 2016 11:43pm |
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| YOLO110 Member Since: 14 Feb 2015 Location: Perth Oz and Stansted UK Posts: 1633 
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Well, perhaps a bit agricultural, but if I was still outback on my mates farm, I would...
Get a gash piece of 48mm tube. Put the 46mm clamp over the tube and bolt it up until snug. Get oxy/acet torch and heat up clamp, then slowly tightening it as the clamp metal softens until it has enlarged the 2mm and is a nice snug fit around the 48mm tube. Remove, repaint, install!  YOLO... You Only Live Once... |
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4th Jan 2016 6:01am |
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| Mike_B Member Since: 23 Jan 2011 Location: Moray Posts: 550 
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I had whitbread weld flat bar across all the corners of my cage. I could then drill the bar and mount a roof rack directly to it. In the end, I didn't bother with a roof rack. The cage was plenty strong enough to carry anything.
Maybe think about some weld-on brackets and fitting phenolic coated ply to the roof. With drilled 70mm holes in the ply above the cage, you can secure items nicely using climbing slings and normal ratchet straps. Pointless paying a fortune for the structural strength and load spreading ability of a roof rack when you already have a cage. You could also fit Unwin rail to the ply if you wanted, allowing endless possibilities for securing kit. If you fit three panels to the cage, one above the roof slope, one above the middle row seats, one above the load space, it looks quite neat. This also allows you to fit the front one as a sloping panel, sitting parallel to the roof, which looks neater. Buffalo board is what is used on the safety devices roof racks http://www.rimmerbros.co.uk/Item--i-GRID012903 Here's an example of weld on brackets, although you could use flat plate like I did.. http://www.bordermotorsport.co.uk/index.ph...er=product Last edited by Mike_B on 4th Jan 2016 12:47pm. Edited 1 time in total |
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4th Jan 2016 11:19am |
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| Mike_B Member Since: 23 Jan 2011 Location: Moray Posts: 550
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Or maybe get someone to fabricate a set of these if your heart is set on a roof rack
Bracket is halfway down the page http://www.eastcoastrover.com/SafetyDevices.html Cibit on here has used a mash panel on his P&P cage. You could do this, although it would've been easier to specify before the fitting! http://www.defender2.net/forum/topic3841.html Here's the DMC defender with panels fitted to the http://funrover.com/history/top-5-best-special-edition-defenders/ Food for thought.. |
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4th Jan 2016 11:25am |
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| Supacat Member Since: 16 Oct 2012 Location: West Yorkshire Posts: 11018 
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Protection & Performance Ltd make aluminium Clamp Sets for 45mm & 50mm Tube
http://www.ppcages.com/wp-content/uploads/2010/05/kitpartlist.pdf You could either pack out the 50mm ones or ask if they will make 48mm as a one off. 
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4th Jan 2016 5:49pm |
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| Mike_B Member Since: 23 Jan 2011 Location: Moray Posts: 550
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I've spoken to P&P before about one offs and they told me to sod off. Too busy to be interested...
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4th Jan 2016 7:40pm |
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