| Custom Tire Carrier Fabrication |
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| First we ran to the local hardware store and bough some stuff for a kit. The kit was composed of: (1) 1994 YJ tire mount 11' of 1" square tubular aluminum (4) grade-5 7/16 x 1-1/2" bolts (4) grade-5 7/16" x 2-1/2" bolts (8) 7/16" washers (4) 7/16" rubber gaskets (8) 7/16" x 1/2" nylon spacers (4) grade-5 6mm x 2" bolts (4) 6mm washers (4) 6mm rubber gaskets (3) wheel lug nuts |
| Our first step was to cut the aluminum into (2) 4' sections (the Crossmembers) and (2) 1-1/2' sections (the Mounting Members). Next we mesured the holes for the crossmember mounting bolts within a 1" square end surface of the Crossmembers. Then we drilled all 4 holes at a 7/16" diameter to fit the crossmember bolts. |
| Here we marked the distance span of the Crossmembers onto the Mounting Members to ensure correct alignment of the crossmember bolts into the Mouting Members. The Mouting Members provide a 1" lift and secure the carrier to the stock rack rails on the XJ |
| Next we alligned the YJ tire mount to the center of the 4' crossmembers and marked 4 holes for the 7/16" bolts. One the wholes were marked we drilled them again with the 7/16" drill bit |
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| Here the tire mount is bolted to the Crossmembers. We put the 7/16" bolt through the washer then tough the tire mount. Between the mount and the Crossmebers we inserted the 7/16" hole rubber gasket to allow flex and less rattleing. Once the bolt was though the 1" crossmember we tightened down and 7/16" nylon lock nut to ensure the mount would not come off. |
| Again, here is the tire mount bolted to the two Crossmembers from an areal view. It was really starting to come together at this point. |
| Next we measured the distance between the existing bolts on the stock rack rails then marked them on the new Mounting Members to drill the holes for the 6mm mounting screws that would thread perfectly in place of the stock bolts that were only 3/4" long compared to our new 2" ones that would fit though the Mounting Members into the rack rails. There are (4) 6mm bolts on each rack rail on the '90 XJ, the Mounting Member spans one distance between 2 bolts. The carrier will be mounted to the 3rd section from the front. |
| Next 3/8" wide x 1" long slots we fabricated to allow access for a standard open-ended wrench to reach the nut of the crossmember bolts becuase we're not boring all the way though the Mounting Members. This is because the Mouning Members will be resting directly on the stock rack rails and there would be no access for a nut to be purged. Plus this looks a lot nicer. |
| Next we mounted the Crossmembers to the Mounting members with our 7/16" x 2-1/2" bolts. We placed the (4) washers on then threaded the bolt though each Crossmember. We put (2) 1/2" nylon spacers beween the Mounting Members and the Crossmembers on the bolts for more clearance. Then we inserted the lock nut though the access slots and tightend it togeahter |
| Here is the finished product product before mouting to the rack rails on the Jeep and before mouting the tire. |
| This is what the carrier looks like mounted to the rack rails on top of the Jeep without a spare on top. The 2" of lift created by the Mounting Members and the nylon spacers gives the Crossmembers 1-1/2" of clearance above the roof of the Jeep. That much lift was needed beacuse the roof has an arch to it and the weight of the tire will cause the Crossmembers to bow slightly. The 1-1/2" of clearance is enough "knock clearance" to prevent the carrier from knocking on the roof during offroading or hitting bad pot holes |
| Here is the final product with the tire mounted on top. The blue tie down strap was added for effect and to hold cargo down to the tire if needed. It is not needed to keep the tire on the rack. As you can see there is about 12" of space to the left and the right of the tire left on the Crossmembers. This space gives us expansion room for a larger tire or to mount a Hi-Lift jack or a shovel. Becuase this rack is made from light weight aluminum and is thin and areodynamic, it only causes as much drag as the tire creates. The carrier without a tire weighs in at less than 10lbs. |
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| OVERALL PROJECT RATING - 5 - Rating 5: Very happy with outcome, design worked well, quick build and great performance |