I needed a very specific Roof Rack for my Jeep Wrangler TJ that I couldn't find online. So I decided to build my own Custom Overland Roof Rack that fit my needs perfectly. I haven't found many videos covering the actual design and build process for TJ roof racks so I hope this will help anyone else that is looking for something similar. This build probably took me about two weeks to finish. I am super pleased with how it turned out. I drove all the way from Ohio to Moab and back doing hard badge of honor trails along the way. The rack held up great with zero issues!

Amazon Affiliate Links:
1/4 Gussets used for Rack Interface - https://amzn.to/3PqzrCZ

Swag Offroad Square Tube Roller Dies - https://amzn.to/3PxQUcN

KC Light Mounts - https://amzn.to/3rqp9L2

Small Gussets - https://amzn.to/3ETkPHn

Kobalt Angle Grinder - https://amzn.to/3Lz9Feu

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Contents

00:00 - Intro
01:00 - Materials & Tools
04:08 - Making the Front Mounts
12:26 - Hardware
13:56 - Making Rear Mounts
20:54 - Bending/Marking/Adjusting Mounts
28:22 - Welding Rack Interface onto Mounts
29:48 - Building the Rack
35:51 - Roof Rack Walkaround
38:56 - Outro
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2004 Jeep Wrangler Sport
4.0 Straight 6 engine
5 Speed Manual Transmission
Dana 44's Front and rear (4.10 gears)
ARB Air Lockers Front and rear
Rubicon 241 Transfer case (4:1 gear ratio)


Jeep Mods
3.5" Metalcloak Dual Rate Springs (Front)
4.5" Metalcloak Dual Rate Springs (Rear)
35" Mickey Thompson Baja Boss M/T
15" Fuel Covert Wheels
Poison Spyder Steering Box Skid Plate
Savvy Cable Shifter
LoD Offroad Signature Series Rear Bumper with Tire Carrier/Jerry Can Mount/Cargo Rack
Quadratec QRC front bumper (cut into stinger style)
Metalcloak Rocker Rails
Metalcloak Extended Corner Guards (Aluminum)
MetalCloak Overline Fenders (Aluminum)
Metalcloak 4" Fender Flares (Front and Rear)
Smittybilt X20 Winch with Synthetic Rope Line
M.O.R.E oil pan/Tranmission skid plate
ARB Air Lockers (Front and Rear)
ARB High Output On Board Compressor
Fox Performance Series 2.0 Shocks
StinkyFab Heavy Duty Aluminum steering
Teraflex Heavy duty ball joints
Poison Spyder Diff Covers (Front and Rear)
Ten Factory Chromoly axle shafts (Rear)
Motive Gear Chromoly Axle Shafts (Front)
M.O.R.E "Bombproof" Motor Mounts with 1" of lift
Ecotric Vented Hood Louver
Decals from Pixel Decals
Hooke Road Interior Cargo Rack
K&N High Performance Air Filter
LED dash/over head lights
Ampper LED Rock Lights
DEI Fuel Rail Heat Sheild
Savvy Aluminum Fuel Tank Skid Plate
Bosch 4 Hole Upgraded Fuel Injectors
Motobilt Tub Armor (Aluminum)
Motobilt Half Door Armor (Aluminum)
Dana 44's Swapped From A Rubicon (Front and Rear with 4.10 gears)
241 Transfer Case Swapped From a Rubicon
Clayton Adjustable Control Arms (Full Set)
Barnes 4WD Transfer Case Skid Plate
Custom Adams Driveshafts (Front and Rear)
Bestop Supertop NX Soft Top
SpeedoHealer (PolyPerformance)
Redhead Steering Gearbox
SwayLoc Dual Rate Sway Bar
MicTuning J1 Phosphorus Headlights
Hooke Road Over Head Molle Panel
Hooke Road Tailgate Table
Custom Built Roof Rack (by me)
Inspired Overland Roof Top Tent
Vanco Big Brake Kit with Black Magic Brake Pads
Mic Tuning J1 Phosphorus Headlights