Avalanche Expedition Rack build

[protohyp]

Been contemplating this for a while after my trailer build and after camping this past week in the back country in mammoth I realized how much I need it.

Spent the past week thinking it through and still not done but here is the start.

Picking up some materials for the sides of the front part of the rack and will be working on that today.

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[rayra]

Aluminum channel? Layout looks pretty good.

What plans for suspension mods, if any?

You should check out member stryder's Avalanche build (if you haven't already), it's pretty heavy duty. He's been steadily adding mods and making some real off-road trips this past year. Was just visiting him this weekend and checking out his new seats and latest compressor / welder mods.

I'll go dig up a link...
eta
https://www.expeditionportal.com/forum/threads/my-02-avalanche-nfe.158253/

 

[protohyp]

Aluminum channel? Layout looks pretty good.

What plans for suspension mods, if any?

You should check out member stryder's Avalanche build (if you haven't already), it's pretty heavy duty. He's been steadily adding mods and making some real off-road trips this past year. Was just visiting him this weekend and checking out his new seats and latest compressor / welder mods.

I'll go dig up a link...
eta
https://www.expeditionportal.com/forum/threads/my-02-avalanche-nfe.158253/

THanks...I'll check out his build.

So far i've only spacer'd and leveled the truck. I need to gain another 2" so may just go with a 4" lift kit so that it will level with the trailer.

I had a bunch of this aluminum sitting around and didn't want to deal with rust with steel. Its pretty sturdy the way I built it. Most of the heavy stuff will go on the trailer but the rack can handle water, and rescue gear as well as other essentials.

I'll be adding stuff as needed but over all i'm pretty happy with the build. Two days on it and i'm getting thumbs up driving around LA.

 

[ttengineer]

Whoa, that’s a big cantilever. I’d be cautious loading anything on that front end. Looks like it’s very likely to ruin your roof, unless it’s connected to the stock roof rack somehow.


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[protohyp]

Whoa, that’s a big cantilever. I’d be cautious loading anything on that front end. Looks like it’s very likely to ruin your roof, unless it’s connected to the stock roof rack somehow.


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Currently it is connected to the stock roof rack but will be hard mounted to the roof eventually


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[protohyp]

Some pics of the front rack side plates. Took a while to template the curve but all in all I like the result.

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[bwiggs]

Great project!

How did you attach the rack to the bed? Is it removable or a permanent install? Do you have any more pics of the install?

 

[protohyp]

Great project!

How did you attach the rack to the bed? Is it removable or a permanent install? Do you have any more pics of the install?

Yeah it’s semi permanent. The rear end of the rack is connected to an L bracket that is bolted to the bed rails. Currently the front of the rail is attached to the factory racks but I will delete those and hard mount to the roof.

I just rebuilt the tonneau cover because it leaked and after some good rains in so cal my new bed cover doesn’t leak and I don’t even finish weather stripping it. Mounted some recovery gear today and will hard mount the Pelican 1650 tomorrow and the water cans.

Here are some more pics

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[protohyp]

Just finished the windscreen with a little surprise




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[protohyp]

Mounts for my maxtrax that got some use after 4wd went down in the snow. Really sucked to have front wheels touching pavement but still can’t get out

Some closeups of the light bar

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[protohyp]

Rig rundown




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[KDB]

Great rack! Solar as well. Very cool. The Avalanche was always a bit challenged in the long rack support department. I always thought the Avalanche shells looked kind lame. Your overland styled rack looks great. Here is what i had done with my Avalanche years back. A company (im forgetting the name of) made the rear rack. Two yakima's on top and two on the bed cover panels. Worked great and could carry a lot of gear. Underneath the boards is my shelter systems dome. Huge ultra light living space. Great baja set up but not too mobile.

 

[protohyp]

Great rack! Solar as well. Very cool. The Avalanche was always a bit challenged in the long rack support department. I always thought the Avalanche shells looked kind lame. Your overland styled rack looks great. Here is what i had done with my Avalanche years back. A company (im forgetting the name of) made the rear rack. Two yakima's on top and two on the bed cover panels. Worked great and could carry a lot of gear. Underneath the boards is my shelter systems dome. Huge ultra light living space. Great baja set up but not too mobile.

Thats cool.

I figured I had a bunch of material sitting around that hadn't been used so I designed it for the systems that I knew I would put on there. Even if there was a lot of support I probably would've fab'd it myself just because they would just get too expensive anyway.

So far it has worked out great. Still have to mount my 60" extreme hi lift jack and start working on the rear bumper and winch. but still have to work on getting 4wd working again.

 

[chilliwak]

Cool rack on that avalanche Mr Pro. Me like....

 

[protohyp]

Just did an upgrade to my ride with Fox 2.5 DSC and Cognito Upper control arms. Such a big difference in ride quality. Can't wait to get them dirty.

Here is a link to install process


This is how bad I was sagging with trailer connected

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