The Irvine Family

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Jeep Safari Rack

Here are pictures of my homemade safari rack for my 1995 ZJ (Grand Cherokee). I made it out of PVC pipe, and it cost me less than $45.00 to make. The project took a little over 4 hours to complete. I will paint the rack black so it looks a little better also. Final inside dimensions - approx. 35"x63".

Materials List:

6 - 1"x10' white PVC pipe
8 - 1" 90º white PVC elbow
34 - 1" white PVC "T"
1 can PVC cement
4 - 1/4-20x2.5" hex bolts
4 - 1/4" washers
4 - 1/4" fender washers
4 - 1/4" lock washers
4 - 1/4-20 hex nuts

I also recommend buying a PVC pipe cutter. Your arm might fall off if you attempt this solely with a hacksaw. Also, i tried to dry fit it first.. it does not work. the PVC joints do not seat fully without glue to help lubricate them. Measure twice, cut once.

One of the bottom ends

The matching top end piece

These are the start of the ends of the sides of the rack.

The bottom assembled. Start with this piece and then add the top of the ends to it. The uprights were cut to 8" which resulted in an inside height of approx. 9.5".

This illustrates how the sides were assembled. One 8" piece of pipe was glued to 2 "T" pieces. then the 2 side pieces (approx. 10.75" long) were glued to them. Be sure that the "T pieces are perfectly parallel! Then make the second identical piece. Then glue the 2 "rungs" together as shown. Be sure to verify there is not twisting as soon as you assemble, you can twist the assembly for a brief time to straighten it until the glue sets. Continue until you have a completed side.

This is just to show what it will look like, the side is NOT glued on at this time.

One assembled side piece. make sure that it is not twisted as you glue it together. Once the glue sets (approx. 15 seconds) you will not get the pieces back apart.

The finished product, ready to attach to the roof rack.

Here it is bolted to the roof rack. The roof rack supports were adjusted approx. 1 foot in from the ends to better distribute the weight. The rack is through bolted, the washer goes on top, the fender washer and lock washer go under the rack with the nut.