Need ideas for custom aluminum fabrication to attach bar to existing Diamondback cover cleats...

[MST Overland]

I want to run a piece of aluminum from one cleat to another across the Diamondback cover. My ideal solution would be to bolt something in place of the existing cleats with tamper resistant hardware so I can attach some fork mount bike racks. I want to avoid drilling into the cover as I may end up with an overland bed rack system next year and don't want to deal with filling holes. Does anyone know of an aluminum extrusion company that may be willing to mount a couple custom ends on a c-channel or t-channel? See red line in photo - that is where the rack would mount across the cover and about 2 inches above. (edit, the truck in the photo is not mine - I think I got it off this forum a few weeks ago...).

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[WLFPIR8]

Build something with extruded tubing and either bolt it all together or get friendly with a welder. Security torx screws work great and deter the unmotivated passerby. 8020 or the like for extruded tubing, to ensure some kind of rigidity. Maybe make a adapter plate that fits the existing bolt pattern on each end, and end mount those plates on a piece of 8020? Then when you mount any hardware to the 8020 you can position it anywhere along the length.

 

[WLFPIR8]

I'm currently trying to figure out how I want to adapt some bed-rack sections to the diamondback cover, so when nothing is mounted on them I can still open the cover.

 

[Trigganometry]

Use square or rectangular aluminum extrusion. After measuring TWICE then cut away ends to leave a tab of one face. Same on both sides. Then bend the tabs down to match the angle of the diamond cover. Use the tie down hasps to transfer the hole patterns. Paint and attach

 

[MST Overland]

How did I not know that this 80/20 existed??? I just checked on a site and they will custom cut sections of all different sizes and configurations at any angle and provide the fasteners and joints that work with it. This particular t-track will allow me to place fork mounts at an angle... Good stuff!

 

[Trigganometry]

How did I not know that this 80/20 existed??? I just checked on a site and they will custom cut sections of all different sizes and configurations at any angle and provide the fasteners and joints that work with it. This particular t-track will allow me to place fork mounts at an angle... Good stuff!

80/20 is some pretty remarkable material with limitless uses. Look at all the extrusion types because there are quite a few. Many of them you can purchase black anodized too. You can fab the stuff yourself with a chop saw and a new carbide blade. Use a wax stick to condition the blade before cuts and it will keep the blade from loading up with aluminum. I use this stuff at work to build automation machines constantly.

 

[WLFPIR8]

Use square or rectangular aluminum extrusion. After measuring TWICE then cut away ends to leave a tab of one face. Same on both sides. Then bend the tabs down to match the angle of the diamond cover. Use the tie down hasps to transfer the hole patterns. Paint and attach

Lol, yes. Mis-cutting extrusion can be a $$$ mistake.

 

[WLFPIR8]

How did I not know that this 80/20 existed??? I just checked on a site and they will custom cut sections of all different sizes and configurations at any angle and provide the fasteners and joints that work with it. This particular t-track will allow me to place fork mounts at an angle... Good stuff!

The stuff is wonderful. Looking into this bed rack system made of the stuff: (1) XTR1 Bed Rack for Ford Ranger – Xtrusion Overland (xtrusion-overland.com)

 

[MST Overland]

Saw this on Instagram today. A company is going to make mounts that attach to the cleat mounts. And it uses standard 80/20 as crossbars.

 

[SOHK_Alumni]

Consider the generic clamp on roof rack cross bars.

Available in a variety of widths, most have locking covers for the clamps. May need to trim the lower clamping lever to fit inside the cleat.

 

[Murph]

I want to run a piece of aluminum from one cleat to another across the Diamondback cover. My ideal solution would be to bolt something in place of the existing cleats with tamper resistant hardware so I can attach some fork mount bike racks. I want to avoid drilling into the cover as I may end up with an overland bed rack system next year and don't want to deal with filling holes. Does anyone know of an aluminum extrusion company that may be willing to mount a couple custom ends on a c-channel or t-channel? See red line in photo - that is where the rack would mount across the cover and about 2 inches above. (edit, the truck in the photo is not mine - I think I got it off this forum a few weeks ago...).

Hey.....Check out my thread! Actually, I like some of your ideas better.

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