DIY Ladder Rack using wood

kozak79 · Aug 14, 2023

I wanted a ladder rack for my Home Depot trips and feel the current options are too expensive or over complicated. I made this design in 3D, and after staining, finished with Spar Urethane. The crossbars will be 3 layers of 1/4" plywood glued over the original crossbars to keep the same curvature. A curved 1"x3" will support the crossbars. I found these U-Bolts on Amazon that fit perfectly.
https://www.amazon.com/dp/B093SPX1B7?psc=1&ref=ppx_yo2ov_dt_b_product_details

Here is the render of the design:

Rivian R1T R1S DIY Ladder Rack using wood 1692388567180

I modeled 2 part Rivian logos to cover the screw holes. The white backing gets screwed in and the black inserts are glued in with CA glue.

Rivian R1T R1S DIY Ladder Rack using wood rivianLogo

Finished rack. "Early American" stain and a few coats of Spar Urethane:

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194643271_iOS

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194747222_iOS

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194650410_iOS

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194657361_iOS

I 3D printed covers for the U-Bolts (they are ugly)

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194701175_iOS

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194710412_iOS

Rivian R1T R1S DIY Ladder Rack using wood 20230818_194726446_iOS

Now it's time to move a ladder...

Marchin_MTB · Aug 14, 2023

Looks good and pretty clever. Have you considered adding diagonal braces on the sides to increase strength?

Also are the flat pieces that sit on the truck also 1/4” plywood?

kozak79 · Aug 15, 2023

Marchin_MTB said:
Looks good and pretty clever. Have you considered adding diagonal braces on the sides to increase strength?

Also are the flat pieces that sit on the truck also 1/4” plywood?

It won’t need diagonal braces since most of the lateral strength will come from the roof rails. The wood that sits on the truck will be 3/4” birch plywood.

COdogman · Aug 15, 2023

I’m no engineer, but the only potential trouble spot I can think of would be the small strip of wood in the middle of the mounts. If that were to break through somehow there would be nothing holding that down. I’m sure there is a way to prevent that from happening.

Nice design!

kozak79 · Aug 15, 2023

Crossbar glue-up

Rivian R1T R1S DIY Ladder Rack using wood IMG_5451

Marchin_MTB · Aug 15, 2023

kozak79 said:
It won’t need diagonal braces since most of the lateral strength will come from the roof rails. The wood that sits on the truck will be 3/4” select pine.

Thanks! Looking forward to seeing how it turns out.

ksujeff99 · Aug 15, 2023

This is great! I look forward to the finished product.

I see this going one of two ways - simple and effective: pocket screws, pine and standard plywood. Or more elaborate with a wood species that takes stain better and resists the weather. Assemble with some dominos or M&T joinery and it'd look good enough to leave on as a statement piece.

Flabirder · Aug 15, 2023

I'm interested in the plans and am considering using pressure treated lumber.

Dark-Fx · Aug 15, 2023

I'd consider making that ubolt plate much bigger.

kozak79 · Aug 15, 2023

Flabirder said:
I'm interested in the plans and am considering using pressure treated lumber.

I'll make the plans available. Make sure you use dry pressure treated lumber. Most that you buy at HD or Lowes will be wet.

kozak79 · Aug 16, 2023

Marchin_MTB said:
Looks good and pretty clever. Have you considered adding diagonal braces on the sides to increase strength?

I ended up adding these braces to the crossbars. This added a lot of strength and stiffness.

Rivian R1T R1S DIY Ladder Rack using wood 1692230844752

kozak79 · Aug 18, 2023

I wanted to cover the screw hole under the cross beams so I 3D printed a template and 2 part logo that is screwed in and then the black parts glued in.

kozak79 · Aug 18, 2023

Finished! Updated original post with latest photos.

SSteveEV · Aug 18, 2023

kozak79 said:
Finished! Updated original post with latest photos.

It's amazing what one can accomplish with a set of handy skills and the time saved from reading too many threads here.
Nice work!
Now you just need to hang a mini swing from them and Gary will have a beautiful new playset.

kozak79 · Aug 19, 2023

Added aluminum top rail and tie-down rings.

DIY Ladder Rack using wood

kozak79

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Marchin_MTB

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COdogman

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