Header Bar Strength?

[k1n3k]

For clarification, I'm talking about the tubes that run from the roll bar to the windshield frame. I *think* those are called header bars, correct me if I'm wrong.

how much weight would you dare strap to those in a dynamic load? I'm planning on building a cargo rack that will be attached in 3 places on each side of the vehicle, the front of the header bars near the windshield frame, on top of the roll bar, and on the rear tubes of the roll bar. The roll bar will be carrying the bulk of the weight, but also I'm not sure how solid the windshield frame is so I'm apprehensive about putting any weight up there. I am doing something fairly unique as i'll be putting grommets in the soft top to let a bolt pass through (6 in total). The bolts can be removed to take the rack off. the soft top will get sandwiched in between the mounts on the roll bar/header bars, and the cargo rack. Neoprene will be used to act as a seal.
So, any thoughts on the strength of the setup? the roll bar really should be taking the majority of the weight in most cases, but if something heavy gets tossed up front it will end up carrying it.

 

[Woodrow]

Short answer: I have no idea.
But I just returned from running the Rubicon with a rack held onto those two bars exclusively. I used bar clamps from Summit (2 on each side), 1” square tubes (2) and a Genright aluminum tray:
https://wranglertjforum.com/attachments/img_9795-jpeg.628259/
https://wranglertjforum.com/attachments/img_9796-jpeg.628267/
And here it is loaded up on the trail.

Inside the Jeep was myself, my wife and our 2 dogs so everything had to go on top. I’d say there was about 150# up there. No issues.

 

[KennethS]

I would be more concerned about the strength of the windshield A-pillars than the side bars that are attached to it. Maybe need the same A-pillar supports used on a cage?

 

[macleanflood]

If you're worried about it you can get brackets...I believe Rock Hard makes a set. (But couldn't find it)..that transfers the load down to the frame.

Look for TJ dash bars.

-Mac

 

[NashvilleTJ]

Short answer: I have no idea.
But I just returned from running the Rubicon with a rack held onto those two bars exclusively. I used bar clamps from Summit (2 on each side), 1” square tubes (2) and a Genright aluminum tray:
https://wranglertjforum.com/attachments/img_9795-jpeg.628259/
https://wranglertjforum.com/attachments/img_9796-jpeg.628267/
And here it is loaded up on the trail.
View attachment 635278
Inside the Jeep was myself, my wife and our 2 dogs so everything had to go on top. I’d say there was about 150# up there. No issues.

Mike - had you not had room inside for both the wife and the dogs, which one goes on the roof rack?

 

[Rickyd]

Mike - had you not had room inside for both the wife and the dogs, which one goes on the roof rack?

The dogs don't have opposable thumbs so....

 

[Woodrow]

Mike - had you not had room inside for both the wife and the dogs, which one goes on the roof rack?

Probably me

 

[Apparition]

Probably me

Where's the trip report?

 

[macleanflood]

Where's the trip report?

My video is uploading. I'll post it to my Operation Phoenix build page here in a bit.

-Mac

 

[Apparition]

My video is uploading. I'll post it to my Operation Phoenix build page here in a bit.

-Mac

Looking forward to it Mac