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  1. #1
    Bald Tire
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    Functional DIY Crossbars for the H3

    Post #9 Shows the updated bracket design.
    Below is the original post w/ images.


    Hey Everyone,

    I just thought i would share my latest project with you all. I made a set of crossbars that I consider to be more functional than the OEM/Aftermarket options at less than half the cost.

    The seed for this project started when I first bought my H3 and got rid of my truck, which was my main lumber hauler. I ignored the idea & the inability to transport large lumber until my wife and I decided we wanted to take a road trip but we wanted the back of the H3 to be a flat platform where we can have a small bed, and a little fridge/cooler for our food. With this new requirement, i decided it was time to make the H3 more functional and ended up with this DIY Crossbars that I think are superior to anything that can be purchased readily for the H3.

    Because of the strength these bars offer, i can use them to carry lumber and equipment. I plan to find some type of storage solution for our clothes and stuff regarding the road trip which can be fastened to the crossbars directly.

    Materials used:
    1x 12 Gauge superstrut - 10ft
    4x 1/2" zinc plated carriage bolt - 2-1/2"
    4x 1/2" zinc cut washers
    4x 1/2" zinc nuts
    1x can of spray can bedliner
    4x custom designed & 3D printed crossbar mounting brackets (my friend 3D printed them for me).

    Total cost was approx $40 in materials
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    Last edited by Zerreitug; 08-10-2018 at 09:50 AM. Reason: Updated with new data referenced.
    HUMMER H3 Replacement Key Fob Shells
    https://www.shapeways.com/shops/baddog-engineering

  2. The Following User Says Thank You to Zerreitug For This Useful Post:

    rascole (07-01-2018)

  3. #2
    El Diablo
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    Nice job!

    Sent from my SM-N950U using Tapatalk

  4. The Following User Says Thank You to alrock For This Useful Post:

    Zerreitug (07-01-2018)

  5. #3
    Bald Tire
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    Good work! Considering something like this since the back of ours is turned flat also to haul the hounds

  6. The Following User Says Thank You to Sowedk For This Useful Post:

    Zerreitug (07-01-2018)

  7. #4
    All Terrain
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    Looks really good! Good price point too since most people want $50 for the crossbars on craigslist
    2008 Hummer H3 Alpha Adventure + Luxury

    Rancho 4in, 38x13.50x18 Toyo M/T on 18x9 Trail Ready Bead Locks, Road Armor Bumper, Smittybilt 10k, Gobi Stealth, RRO Sliders, Daystar 1" Body Lift, ARB snorkel, Runcool Hood Louvers, JKS front discos, Coverking Seat Covers, Schwarttzy Skid Plates + Leaf Mounts + Extended Shackles, Outfitter Design Tire Rods, Optima D34, Smittybilt Storage Drawer, 2" T-Bar Crank, HP Tuners Cobra 29 ltd, Dual 102" CB Whips

    Parts List Updated 8/10/18



  8. The Following User Says Thank You to Acer4LO For This Useful Post:

    Zerreitug (07-01-2018)

  9. #5
    Low Profile
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    I like it!

    I have had bad experience with printed parts, but for this applicable with a primary compression load it should work great!

  10. #6
    Bald Tire
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    Quote Originally Posted by mdocod View Post
    I like it!

    I have had bad experience with printed parts, but for this applicable with a primary compression load it should work great!
    Thanks mdocod, I dont have much reservations with 3D printed parts. I think it is just a matter of the material used to create the part. My friend gave a suggestion to modify the 3D model to accept a bushing of equal height to the printed part that serves as the load bearing portion. Its a good idea so i may do a redesign in the near future. I am always up to improving the design. Now i just need to test it and put it through its paces.
    HUMMER H3 Replacement Key Fob Shells
    https://www.shapeways.com/shops/baddog-engineering

  11. #7
    Super Swamper
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    Neat, but personally I'd get some aluminum bar to use for the spacers, the roof channels are level with each other so that's not an issue. I used some 1" tall x 1.25" wide bar for spacers for my roof basket and it works great.

    Sent from my SM-N950U using Tapatalk
    2008 H3 Alpha

    "Live free or die: Death is not the worst of evils." - General John Stark

    N1JPA

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    Zerreitug (07-05-2018)

  13. #8
    Bald Tire
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    Quote Originally Posted by JPaul View Post
    Neat, but personally I'd get some aluminum bar to use for the spacers, the roof channels are level with each other so that's not an issue. I used some 1" tall x 1.25" wide bar for spacers for my roof basket and it works great.

    Sent from my SM-N950U using Tapatalk

    Thats cool JPaul, do you have any pictures you can share?
    HUMMER H3 Replacement Key Fob Shells
    https://www.shapeways.com/shops/baddog-engineering

  14. #9
    Bald Tire
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    UPDATED!!!! Mounting Brackets Re-design

    Well after a month of testing my crossbars, i will say that they are performing exceptionally well. I love the strength of the superstrut. I ended up re-designing the mounting brackets for ease of adjustment. Before i had to loosen up a (mostly inaccessible) bolt and the whole crossbar would be susceptible to shifting off. With my new design, the crossbars stay firmly attached to the mounting bracket, but the bracket itself is easily able to be loosened & adjusted to a desired length.

    I changed the material used as well because the old ones suffered some deformation due to high heat. This material is a carbon fiber reinforced plastic with a rubber gasket making contact between the mounting bracket and the mounting rails. The finish is also much better with these.

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    HUMMER H3 Replacement Key Fob Shells
    https://www.shapeways.com/shops/baddog-engineering

  15. #10
    All Terrain
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    I think you've built up an interest in this design; including me.

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    Zerreitug (08-10-2018)

  17. #11
    All Terrain
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    There is nothing to prevent a side load shift? Without even a lock washer, If they loosened a tad the whole rail appears to be able to slide right off either side.
    06 H3 Adv - Great, another project.
    09 H3T Alpha/Adv- Sold

  18. The Following User Says Thank You to Traxx For This Useful Post:

    Zerreitug (08-10-2018)

  19. #12
    Bald Tire
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    Traxx, Thanks for the perspective. Although I have driven 300 miles with the new brackets, there has been no signs of the nuts loosening up with normal vibrations. I think the rubber pad i have under the brackets are helping with that.
    However, that is a valid concern and I will definitely look into a solution for that. Thanks for the input.

    Quote Originally Posted by Traxx View Post
    There is nothing to prevent a side load shift? Without even a lock washer, If they loosened a tad the whole rail appears to be able to slide right off either side.
    HUMMER H3 Replacement Key Fob Shells
    https://www.shapeways.com/shops/baddog-engineering

  20. #13
    Baja
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    Nicely executed. I do agree that the side loading could be an issue. A simple fix would be to use a nyloc nut or a castle nut with cotter pin. I like the second try a lot better.

  21. The Following User Says Thank You to Happy Hummer For This Useful Post:

    Zerreitug (08-14-2018)

  22. #14
    Bogger
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    Very nice. I am interested in these. When will you start production?
    Cheers, Doug In Colorado
    K0LEF 146.460 simplex


    I am sorry that everyone cannot own a Hummer; some folks have to drive a Jeep or a Toyota.

  23. The Following User Says Thank You to DJinCO For This Useful Post:

    Zerreitug (08-14-2018)

  24. #15
    All Terrain
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    I'll throw this out there.

    Www.mcmaster.com

    33085T78. this same unistrut in stainless to the nearest ft

    3230T26. Aluminum unistrut.

    3312T63. Plastic end covers in selectable colors to keep from shredding your forearms on the cut ends

    Pick your stainless hardware to match your application.
    Last edited by CaseyS; 08-13-2018 at 10:01 PM.


 

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