Fully adjustable, quickly removable, low profile van rack for windsurfing

prusaprinters

<p>I needed a very low profile rack system for my gear as wind variation here extreme so need to pack lots in. &nbsp; Also needed to be able to quickly adjust the racks to suit various gear and also remove the whole rack system quickly in order to sleep in the van. &nbsp;This the result.</p><p>The pillars are made from 38 x 16mm rectangular Aluminium and the crossbars from 12x8.8 and 16x12.8 Aluminium tube. &nbsp; &nbsp;The crossbars will be reinforced with 8x6mm carbon tube but this is on order.</p><p>For my van the right hand side has vertical supports due to the cupboards but the left side has supports at 12deg to match the van profile. &nbsp;This meant the cross bars also needed to be adjustable. &nbsp;A fellow windsurfer had used adjustable tent poles for their rack. &nbsp; &nbsp;Looked into this but adjustable twist lock tent poles cost crazy money. For the same price of one tent pole could buy 2 x 6.5m lengths of Al tube, and a roll of filament.&nbsp;</p><p>Took a few attempts but the twist lock cams were very easy to design and print and worked far better than expected. &nbsp;The larger version easily held my own weight (80Kg). &nbsp;I tried the next size down and that too far exceeded expectation so I went with the smallest Al tube combo for the van rack. This was still at least 10Kg. &nbsp;</p><p>The cam lock vertical supports also held far more load than expected. They use 6mmx35mm bolts (ideally stainless) with lock nuts. &nbsp;The cross bars I contact cemented 3mm foam and the job was done. &nbsp; After removing windsurf gear it takes less than 1 minute to remove rack system and bed up for the night. &nbsp; I keep the verticals in place for sleeping but if needed they can be removed quickly as they fit into the sliding seat racks as seen in photo.</p><p>The top bars either slot into the top holders or a simple wing nut (see photo)</p><p>All the crossbars double as tent poles, roughly 1m expandable to 2m for my case. &nbsp; &nbsp;If you want to just use the crossbars and increase the crossbar diameter, you can find 3 different sizes here: &nbsp;<a href="https://www.printables.com/model/232086-adjustable-twist-lock-tent-pole">https://www.printables.com/model/232086-adjustable-twist-lock-tent-pole</a></p><p>In Australia you can purchase the Aluminium extrusion at Capral &nbsp; &nbsp;Note their website sometimes doesn't show the small diameter tubes 12mm or 10mm but calling or turning up shows they stock it.</p><p>&nbsp;</p>