Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
DIY Spare wheel, hi-lift and canister mounts
Welcome again Chaps
Having a roof tent is a great comfort and wouldn't change it for anything since we've been using it, but unfortunately there is no more space on the roof rack for other things.
Last year, when we were travelling through Scotland, decided to take spare tyre only as finding a place to replace it in case of puncture would be probably quite easy. The tyre can be mounted on top of the hard shield roof tent as it is capable of lifting 20+ kg, so having in on top was not a problem.
This year we are planing to travel through Georgia and Armenia - planned route goes through high mountains, and places far from any civilization so having just spare tyre wouldn't be enough. The whole spare wheel is too heavy to have it on top of the tent.
Travelling with the dog in the boot and having big wheels makes it difficult to find a place for a spare one. So that's why decided to build my own mounting system.
Visited my friends - specialists in welding stainless steel. Had a brain storm, went through the solutions available on the market and started our own project
First stop - shop with the stainless steel profiles and panels.
Than had to decide where I wanted the wheel to be. Wanted to fit it in a place that doesn't cover the rear light and there could be enough place for canister for additional 20l of fuel.
The concept was to use stainless 50mm tubes welded to the rear part of the frame. Than, 1mm smaller in diameter tube would be used to fit in. Had to cut both ends of the bar.
Tube welded in.
And after few shots of whisky night spent in the workshop in the back of the car
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
13th Jun 2015 4:18 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Another day started from fitting the smaller pipe in to check how it fits
Everything was perfectly placed, so after putting the rear bumper back on again, cut the holes and measured the length of the inner pipe that would hold the main brackets. Than the tubes were cut and little hole was drilled on the bottom to secure it from the bottom with the screw.
It was a good time for renewing the rear bar - it was sanded and painted against rust.
Main brackets welded into the tubes
Strong enough I think
On the bottom of the outer tube you can see a 1cm Teflon gasket, so the movement is smooth.
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
13th Jun 2015 4:25 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Gallows pole being welded
Few more bars added to make it fully secure and strong enough.
Spare wheel on its new place 8)
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
Last edited by Simon.pl on 13th Jun 2015 4:32 pm. Edited 1 time in total
13th Jun 2015 4:31 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
Excellent stuff, enjoying reading your posts
13th Jun 2015 4:31 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Thanks Tayaste! Wish english was my native language - would create more advanced descriptions, but I hope pictures says it all Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
13th Jun 2015 4:33 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
I see nothing wrong with your English
13th Jun 2015 4:38 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Started to build basket for the canister 8)
Wanted to be as light as possible so decided to use stainless steel pipes bent to shape.
Whoa-la!
To avoid unexpected movement of the brackets decided to use dumpers.
Checking the best place to fit it on the bumper.
And welding the mounting point in.
The mountings will be secured with the screws.
Not the best solution taking into consideration amount of work you have to do letting the dog out, but will think of it when we are back from our trip 8)
Final solution
And few more pics
Will make few more details and download it later
Just noticed I haven't took any pictures of the jack supporter
Will do later on Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
13th Jun 2015 4:46 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
And all fits perfectly around the pro-speed ladder?
13th Jun 2015 4:58 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
No problem at all.
I was afraid at the beginning that the wheel would be too far on the back. In fact it touches the ladder - but it was intended - it dumps the shaking/movement while driving, so the ladder works as an additional supporter
Just having this photo for now.
Will make few more from the distance later on Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
13th Jun 2015 5:04 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
View from the rear camera has changed a little
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
15th Jun 2015 11:23 pm
Iceman08
Member Since: 22 Sep 2014
Location: Hereford
Posts: 2284
Good write up, theres nothing better than making a solution to a problem
Your English is just fine too 8)
15th Jun 2015 11:39 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Glad you've enjoyed it Iceman08
Yeah - very happy from this setup Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
15th Jun 2015 11:44 pm
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1788
Nice work, very inventive, looks like you've thought of everything there
16th Jun 2015 6:55 am
lynalldiscovery
Member Since: 22 Dec 2009
Location: Maidstone
Posts: 7274
Thinking of your bottom bumper fittings, next time you see a merc sprinter panel van have a look at the rear door bump stops as they are magnetic and pretty powerful.
16th Jun 2015 7:21 am
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Thanks a lot Biffysun!
Will have a look Iynalldiscovery, thanks - although think I wouldn't trust anything that is not "screwed in" The spare wheel is darn heavy - wouldn't like to see it open while driving..
But - have no idea of what solution you are talking about so will definitely have a look
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
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Nice work, very inventive, looks like you've thought of everything there 
