Roof rack on a 2021 HR EX
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I am planning to build my own rack for my HR 148. I plan on full aluminum plate and either round welded aluminum cross bars or 8020, depending on cost. AL is stupid expensive right now.
My van & this image is NOT the extended model, but you should just be able to add ~18 inches i think.
The 3033mm is from the two red marks, end of my rack to the front corner. I tried to make a nice transition from the angle of the roof to the rack. Gives me a slick spot for a light bar in the faring too! Van drawing is from the BEMM site.
![151047]()
Crappy rendering is on my van
![151048]()
My van & this image is NOT the extended model, but you should just be able to add ~18 inches i think.
The 3033mm is from the two red marks, end of my rack to the front corner. I tried to make a nice transition from the angle of the roof to the rack. Gives me a slick spot for a light bar in the faring too! Van drawing is from the BEMM site.
Crappy rendering is on my van
That should not be difficult to achieve in your case. I have two 210 watts each Newpowa panel and Flatliner roof rack (I am too lazy to make my own)
Excellent quality but made in China. Not as nice looking as Aluminess, but do the job for my need.
We cut a few inches off the 12' extrusions for the long side-rails. Ended up removing the cross-bar on the back and the planned extra 2 x 50w panels back there. We'll still use those rear points for light-mounts. Gotta make a front fairing eventually... 🤔
If you won't go all the way to the back, 10' extrusions for the sides are fine. And then you won't need those rear brackets, either.
I gotta build an actual parts-list for this.Roughly:
3' 3" angle aluminum, 1/4" thickness, 1/4" radius (cut to ~3" wide each (5-6 per side)
HDPE - 1" thick (https://amzn.com/B003HEWUFO)
10-12 M10 bolts (https://amzn.com/B07K5ZBFWS) (add washers and/or lock-washers as you see fit)
2x 12' aluminum extrusion (or less)
Cross-members as you see fit.
![151111]()
If you won't go all the way to the back, 10' extrusions for the sides are fine. And then you won't need those rear brackets, either.
I gotta build an actual parts-list for this.Roughly:
3' 3" angle aluminum, 1/4" thickness, 1/4" radius (cut to ~3" wide each (5-6 per side)
HDPE - 1" thick (https://amzn.com/B003HEWUFO)
10-12 M10 bolts (https://amzn.com/B07K5ZBFWS) (add washers and/or lock-washers as you see fit)
2x 12' aluminum extrusion (or less)
Cross-members as you see fit.
Thanks! That looks good. Does the fan work good being back there? I need to put my fan, a 315 watt panel and a mach 8 cub AC unit. Afraid it might be tight.
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I am used to seeing only 5 mounting pads on each side. Did you invent the sixth, or is there a pad I wasn't aware of?
How long are your cross members?
One of the reasons I bought the Flatliner roof rack was their 5 to 6" sidewall rail. It hides the solar panels and gives a cleaner look. It is perfect to mount Fiamma awning.
For this van build thing, I have gone deeper and deeper end. I may die before this thing is finished.
For this van build thing, I have gone deeper and deeper end. I may die before this thing is finished.
Feeling the same way! and I dont even have my van yet. I have built and rebuilt it on paper a thousand times. For look i am going to use the 15 series so it is same as the panel. But I may use the 3" on the sides to add an awning if and when they are in stock again.One of the reasons I bought the Flatliner roof rack was their 5 to 6" sidewall rail. It hides the solar panels and gives a cleaner look. It is perfect to mount Fiamma awning.
For this van build thing, I have gone deeper and deeper end. I may die before this thing is finished.
I bought so much stuff (parts and tools) for the van, I don't remember what I have in the garage. Ordering on line is easy, putting it on takes effort and time.
AMEN!
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88 Posts
Some builders don't worry about max length of the van - as seen it this shot from VanDoIt's web site.
Interesting.
Fan there is great. But gotta have windows open in the front - or some sort of vent because that thing FLOWS air; we just crack the front windows so far.
If AC, I'd assume AC in the rear and something else in the front. Maybe the small circle-vent/van things? Or vice-versa? I think the AC units use the same 14" opening as the fans - but placement is a question. I looked at one AC unit that is wide but not long - could basically replace the fan location on ours with it from what it seems. Hopefully, we'll continue to avoid places hot enough to need that; we're out to run / hike / climb / bike / snowboard and none of those go well in the heat, really.
Astute, @BobCollins : I added two rear mounts by sandwiching two pieces of HDPE inner/outer with washers and bolts over the factory "hole" there. Then gooped it. It doesn't leak (yet). It doesn't carry weight; just there to mount lights at this point.
I think they were right at 6' - give or take. I could have adjusted a couple inches either way (width-wise) by changing the mounts - could've used wider or taller angle-aluminum. I had planned mounting the panels on TOP all along, so I just needed it about right - not exact. The panel piece is one big framed unit that can tilt to optimize solar. I haven't added actuators to it yet, though. The panels are these ones and they're framed with 3030 aluminum, so... size?
I am going to put the fan in the back and ac towards the front. Than I can pull the air back over the bed. I am putting one big 315w panel up so if I can maybe put it across the van that will make it easy. If not I will have to get creative.
Thanks again for the info.
Just realized I screwed up that width post: FIVE FEET, not 6'. Right at 60".
With 11+ feet on length, there's plenty of room in there. Might want to consider order of priority. If the AC unit can act as a fan on its own, then the other fan is probably not essential (unless the AC's airflow is poor). Just a thought. I think I've seen that AC unit offset to the side before as well. Or consider the other AC units that don't take up so much space if you're going center-mount.
Not that solar is important... if you've got the dual alternator setup, you can put 3-4 times that panel into the batteries with the engine idling. 800w of panels on mine; but the engine will put over 1kW (max I've seen is about 1.4kW) with or without sunshine. I sure didn't expect that to go as well as it did... 😁
With 11+ feet on length, there's plenty of room in there. Might want to consider order of priority. If the AC unit can act as a fan on its own, then the other fan is probably not essential (unless the AC's airflow is poor). Just a thought. I think I've seen that AC unit offset to the side before as well. Or consider the other AC units that don't take up so much space if you're going center-mount.
Not that solar is important... if you've got the dual alternator setup, you can put 3-4 times that panel into the batteries with the engine idling. 800w of panels on mine; but the engine will put over 1kW (max I've seen is about 1.4kW) with or without sunshine. I sure didn't expect that to go as well as it did... 😁
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