Ford Transit Custom Aluminum Roof Rack Build

Ford Transit custom aluminum roof rack - hero

FabricationAluminumTransit 250Roof RackOverland

Overview

A custom Transit rack built to carry real gear without adding weight, noise, or catalog-rack pricing.

I designed this rack in CAD for my 2015 Ford Transit 250 medium-roof short-wheelbase van. It uses .125-wall aluminum tube in 3x1 and 1-1/2x1-1/2 sizes, with every joint TIG welded. It bolts to the six factory roof points, so the rack itself doesn’t require drilling new holes in the van.

The layout clears the vent fan and air conditioner while still leaving useful solar real estate. It’s finished in hammered black powder coat, and after years of daily use it has stayed quiet, solid, and worth the time it took to build.

Goal

Build a light and durable rack that fits my equipment and budget without paying luxury rack prices.

Approach

TIG-welded .125 wall tube, factory mounting points, smart layout for A/C, vent, and solar - no roof penetrations for the rack.

Function first. Factory mounts, clean welds, and a finish that holds up.

At a Glance

Platform

2015 Ford Transit 250 - Medium Roof, SWB

Material

3x1 and 1-1/2x1-1/2 aluminum tube - .125 wall

Build

CAD design - saw cut on horizontal bandsaw - fully TIG welded

Mounting

Six factory roof rivet nuts - no new holes for rack

Finish

Hammered black powder coat

Features

Clears A/C and vent - solar panel mounting - expandable layout

My Take

Roof racks should earn their spot. I wanted a rack that is light, quiet, and easy to live with - not decorative tubing at a luxury price. Using factory mounts keeps the roof sealed and service simple. The welded aluminum frame saves weight without giving up strength.

What I’d Do Next

Reconfigure solar for more output and cleaner cable routing.
Add a retractable awning with dedicated brackets.
Low-profile perimeter lighting with a fused relay block.

Highlights

Structure

.125 wall rectangular aluminum tube
Fully TIG welded joints
Stiff where it counts - light everywhere else

Integration

Uses factory roof points - no drilling for the rack
Clears vent fan and roof A/C
Solar-ready deck with room to expand

Want one like this?

Designing a rack for your vehicle - or building one - I can help.

Tell me your roof gear, mounting needs, and budget. I will design a rack that fits your setup - not a catalog guess.

Start a project

Contact

Want help designing a rack for your vehicle, or want me to build one for you? Send a message and I will get back to you right away.