Roof rack prject - minimalist and a bargain
10-05-2013 | 09:23 AM
#1
Thread Starter
Joined: 07-28-2013
Posts: 2
From: Detroit MI
Roof rack prject - minimalist and a bargain
Hi,
So I needed roof racks (for my surf board), but I don't like the big chrome knuckle look of the dealer accessory. Plus I hated the ridiculous price. So I went looking for an alternative.
As you may know, automotive design engineers love carry over items. It saves design validation time. Well I figured out that the dimensions of the channel in the roof rails of the HHR, are the same as older GM vehicles. So, I was able to go to Pick-your-part (self service salvage yard) and pull the cross bars off of a '90s GMC Jimmy (Chevy Blazer would have worked too).
Now the T joint fit perfectly in the HHR rails, but the cross bars were the wrong shape of course. So you have to plan out the shape of the span, and cut and bend to fit. From my experience know that you don't want to bend too sharp or have to correct your bend. The aluminum is not too forgiving. And you have to drill new holes for the T joints. But really it's not hard.
Then just to be 'minimalist' and 'OEM' I painted them with body color matching spray paint (thank you internet).
Total cost about $60 plus 3-4 hours labor. That includes a second trip to Pick-your-part to replace one cross bar I over-stressed in bending.
Photos here...
http://www.flickr.com/photos/8784101...7636212625284/
So I needed roof racks (for my surf board), but I don't like the big chrome knuckle look of the dealer accessory. Plus I hated the ridiculous price. So I went looking for an alternative.
As you may know, automotive design engineers love carry over items. It saves design validation time. Well I figured out that the dimensions of the channel in the roof rails of the HHR, are the same as older GM vehicles. So, I was able to go to Pick-your-part (self service salvage yard) and pull the cross bars off of a '90s GMC Jimmy (Chevy Blazer would have worked too).
Now the T joint fit perfectly in the HHR rails, but the cross bars were the wrong shape of course. So you have to plan out the shape of the span, and cut and bend to fit. From my experience know that you don't want to bend too sharp or have to correct your bend. The aluminum is not too forgiving. And you have to drill new holes for the T joints. But really it's not hard.
Then just to be 'minimalist' and 'OEM' I painted them with body color matching spray paint (thank you internet).
Total cost about $60 plus 3-4 hours labor. That includes a second trip to Pick-your-part to replace one cross bar I over-stressed in bending.
Photos here...
http://www.flickr.com/photos/8784101...7636212625284/
Very nicely done, and handy info too!
05-11-2014 | 07:19 AM
#5
Premium Member
Joined: 03-17-2012
Posts: 1,039
From: Bay Area, CA
Can you upload the pics with https://imgur.com/ ? They are not loading at all for me and I'm not even on mobile!
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Lowboy44
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05-05-2014 05:39 PM