Let's talk Bed Racks for Tonneau Covers

[AdventureLab]

Any concerns of left and right racking when taking turns? It's looks really solid, but I've never seen them in person before.

How far up do the risers go into the cross bars and how are they attached?

Not at all, but I appreciate the opportunity to explain why. If you'll notice red arrows below, that's four fasteners on each cross rail, on each side spread apart pretty far. Arguably, we could have done away with one of those on the bottom arrows, but due to reusing the same crossbars with the taller risers, that brought along an extra hole. All of that clamping force is going to make for a very rigid system and very flexible with accessories. We're pretty good about putting enough mounting points to future-proof the products and create the flexibility to build a ton of optional accessory mounts (ex. awning brackets, second level risers, as mentioned by @PatrickT).

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[AdventureLab]

I currently run a set of mid height bars at the same time as full height bars. It gives me two layers to mount things. I put a spare tire on the mid height bars and put 4 kayaks on the top bars. My tonneau cover rolls up with plenty of room under tall of that.

cool setup!

 

[clarke]

Not at all, but I appreciate the opportunity to explain why. If you'll notice red arrows below, that's four fasteners on each cross rail, on each side spread apart pretty far. Arguably, we could have done away with one of those on the bottom arrows, but due to reusing the same crossbars with the taller risers, that brought along an extra hole. All of that clamping force is going to make for a very rigid system and very flexible with accessories. We're pretty good about putting enough mounting points to future-proof the products and create the flexibility to build a ton of optional accessory mounts (ex. awning brackets, second level risers, as mentioned by @PatrickT).

I was thinking they might attach like that. Thanks for the confirmation!

 

[AdventureLab]

Here's the first proof of concept for the bed rack risers. These will be sold as 10" risers, just enough to clear the BAK Revolvers. I'm blown away with how sturdy these are. They exceeded my expectations by far. The bases and risers being 3mm steel turned out great!

I was only going to offer this in the 3 rail configuration, but after serious pushing and pulling on these, that is definitely not necessary. Two rails is going to work great. I'll work on a long MOLLE panel to go between the rails, but this configuration with easy access to the bed is definitely a cool setup.

These are the original rails. No modifications were needed to be compatible with the 10" risers.

 

[el_sabio]

Here's the first proof of concept for the bed rack risers. These will be sold as 10" risers, just enough to clear the BAK Revolvers. I'm blown away with how sturdy these are. They exceeded my expectations by far. The bases and risers being 3mm steel turned out great!

I was only going to offer this in the 3 rail configuration, but after serious pushing and pulling on these, that is definitely not necessary. Two rails is going to work great. I'll work on a long MOLLE panel to go between the rails, but this configuration with easy access to the bed is definitely a cool setup.

These are the original rails. No modifications were needed to be compatible with the 10" risers.

Nice!!

 

[MoBob]

Those look really good.

A couple questions. On the panel between the extensions, can it be a partial panel that still allows someone to reach into the bed from the side under the panel, instead reaching over the panel?

How do they attach? Is there a set of shims that come with the bars? Has anything been done to help with water intrusion in the bed when rain hits the upright and runs down it into the bed. I am just planning and trying to understand potential challenges with the setup.

Great work.

 

[AdventureLab]

Would anyone be interested in long side MOLLE Panels for the two-rail setup that opened up for easier access into the bed? We did that for a Gladiator version and it worked pretty well.

 

[clarke]

Here's the first proof of concept for the bed rack risers. These will be sold as 10" risers, just enough to clear the BAK Revolvers. I'm blown away with how sturdy these are. They exceeded my expectations by far. The bases and risers being 3mm steel turned out great!

I was only going to offer this in the 3 rail configuration, but after serious pushing and pulling on these, that is definitely not necessary. Two rails is going to work great. I'll work on a long MOLLE panel to go between the rails, but this configuration with easy access to the bed is definitely a cool setup.

These are the original rails. No modifications were needed to be compatible with the 10" risers.

Them being that sturdy gives new a lot of hope for full height risers to use for light stuff like a canoe.

Why did you go with steel instead of aluminum? Rigidity?

 

[clarke]

Would anyone be interested in long side MOLLE Panels for the two-rail setup that opened up for easier access into the bed? We did that for a Gladiator version and it worked pretty well.

Do you have a video of the ones you made for the Gladiator? I'm honestly too short to reach into my bed from the side, so molle panels that opened up would mostly be used to allow for rolling up the tonneau cover.

 

[AdventureLab]

Do you have a video of the ones you made for the Gladiator? I'm honestly too short to reach into my bed from the side, so molle panels that opened up would mostly be used to allow for rolling up the tonneau cover.

I don't see any videos, but here are a couple of photos to give you an idea. We could possibly put them on struts so they would stay open while you rolled the cover. That would be a pretty cool setup.

 

[sikedsyko]

I'd love to see how much a wheel on bike carrier (like Kuat Piston SR) hangs off the back of the truck if you mounted it on top of the rails.

Personally I would prefer to avoid side molle panels blocking access to the side. I'm imagining the 2 riser rack will be plenty strong for my use case once gear is bolted to the top connecting the rails.

 

[AdventureLab]

I'd love to see how much a wheel on bike carrier (like Kuat Piston SR) hangs off the back of the truck if you mounted it on top of the rails.

Personally I would prefer to avoid side molle panels blocking access to the side. I'm imagining the 2 riser rack will be plenty strong for my use case once gear is bolted to the top connecting the rails.

I was blown away with how sturdy this design is built out of steel. Traditionally we build these risers out of aluminum to save weight. Due to the extra leverage, I changed them to steel and put an extra vertical flange on the base brackets near the attachment bolts. That is the key! These things are stout. I don't feel the MOLLE Panels are necessary for lateral rigidity. They would be more for attaching gear. I could definitely throw a Piston Pro up there for some photos. I have one at the shop we use for testing. Glad to do that for you. May be able to do it today.

Here's a similar setup on the Gladiator (full height) with our ATLAS (Articulating Tent Level and Slide) system. It may give you some perspective while we wait for the photos.

 

[sikedsyko]

I was blown away with how sturdy this design is built out of steel. Traditionally we build these risers out of aluminum to save weight. Due to the extra leverage, I changed them to steel and put an extra vertical flange on the base brackets near the attachment bolts. That is the key! These things are stout. I don't feel the MOLLE Panels are necessary for lateral rigidity. They would be more for attaching gear. I could definitely throw a Piston Pro up there for some photos. I have one at the shop we use for testing. Glad to do that for you. May be able to do it today.

Here's a similar setup on the Gladiator (full height) with our ATLAS (Articulating Tent Level and Slide) system. It may give you some perspective while we wait for the photos.

Thanks, that gives me a pretty good idea. Would be a decent amount of overhang mounting them behind the cab glass.

 

[AdventureLab]

Thanks, that gives me a pretty good idea. Would be a decent amount of overhang mounting them behind the cab glass.

Yes, there will. I'll get some photos on the Ranger this morning.

 

[AdventureLab]

Those look really good.

A couple questions. On the panel between the extensions, can it be a partial panel that still allows someone to reach into the bed from the side under the panel, instead reaching over the panel?

How do they attach? Is there a set of shims that come with the bars? Has anything been done to help with water intrusion in the bed when rain hits the upright and runs down it into the bed. I am just planning and trying to understand potential challenges with the setup.

Great work.

Sorry I missed your questions earlier.

If it's a partial panel, I'm not sure it would add much value. There wouldn't be much surface area there, but I'm always open to things like that if there is enough demand. With the stiffness of these risers, the MOLLE Panels are not going to be required as initially expected.

Yes, there is, what we call, a "dynamic shim stack" that comes with each rail. Depending on the install position the stack needs to be taller or shorter. They are made from 5052 aluminum.

As for water, I would suggest a rubber gasket below the upright. We haven't spent time on that yet, but I have seen a few people here on the forum do just that with good success. I believe @Aemonn can speak to that in more detail.

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