Easiest way to make these awning brackets

[Phil_D]

Morning chaps!

I've got a van with a roof rack ive made from 4040 aluminium extrusion, and just got a brand new second hand awning for it. Mounting to the roof rack is going to require custom brackets, so just looking at whats the easiest route is going to be.

Theres a company which produces these brackets (in the states) which would be ideal. Obviously they are horrifically expensive for what they are, but its basically what im after.

measurements needed are roughly 120mm x 60mm ish, 120mm wide. Probably looking at 5-6mm thick mild steel. I was hoping that places like metals4u would have a big range of mild steel T section that i could literally buy a couple of peices of pre cut to length and just drill some holes. However the largest T section i can find is 50x50mm.

Choice of aluminium T section however is much more vast but im concerned about strength as the awing probably weighs 20-25kg and if a bracket snapped on the motorway it would be catastrophic...

Is this concern justified do you think?

What other options are there for making these with no welder available? Im currently looking to see if maybe cutting a bit of RSJ up would be possible

 

[Maker]

Does it strictly need to be a Tee? Looks like a bit of angle would do the job.

 

[Agroshield]

I do not understand your dimensions. Please draw on your picture or make a dimensioned sketch.

Aluminium Tee Section 101.6mm x 101.6mm x 6.35mm (4" x 4" x 1/4") | Aluminium Online

Shop Aluminium Tee Section 101.6mm x 101.6mm x 6.35mm (4" x 4" x 1/4") at Aluminium Online. Next-day delivery available across the UK. Select your width,

www.aluminium-online.co.uk

https://www.metals4u.co.uk/materials/aluminium/aluminium-i-beam

As above, make from two pieces of 3mm angle back-to-back and a piece of flat plate to tie them together. If you cannot get 3mm angle in a long enough leg length, buy thicker with longer legs and file it down.

Unless they are quite long, the weakest point of the whole structure will be the T-nuts bolting the bracket to the extrusion.

 

[123hotchef]

I made my awning brackets from some heavy duty strap from toolstation

 

[Phil_D]

Does it strictly need to be a Tee? Looks like a bit of angle would do the job.

potentially not, and if its going to be a faff then angle is the fall back plan. Angle brackets would need to be bolted on the underside of the rack to avoid the awning being to high, toward s the middle of the rack there isnt much clearance underneath due to the roof profile but still might be doable.

 

[Phil_D]

I do not understand your dimensions. Please draw on your picture or make a dimensioned sketch.

Aluminium Tee Section 101.6mm x 101.6mm x 6.35mm (4" x 4" x 1/4") | Aluminium Online

Shop Aluminium Tee Section 101.6mm x 101.6mm x 6.35mm (4" x 4" x 1/4") at Aluminium Online. Next-day delivery available across the UK. Select your width,

www.aluminium-online.co.uk

https://www.metals4u.co.uk/materials/aluminium/aluminium-i-beam

As above, make from two pieces of 3mm angle back-to-back and a piece of flat plate to tie them together. If you cannot get 3mm angle in a long enough leg length, buy thicker with longer legs and file it down.

Unless they are quite long, the weakest point of the whole structure will be the T-nuts bolting the bracket to the extrusion.

does this help?

Yes theres a lot more options in aluminium but im just concerned of failure over time as its a fair bit of weight that will be on the brackets and a lot of vibrations etc. Maybe I shouldnt be concerned though?

 

[Phil_D]

I made my awning brackets from some heavy duty strap from toolstation

lets see a pic!

 

[Brad93]

You're not gonna snap 6082-T6 if you can get suitable T-section

 

[Dee J]

Two bits of steel angle back to back look the way to go. Double thickness 'leg' over the roof rack and up and down tabs for the awning. With the hole spacing probably 50mm/2" would do. Bed angle or fence post offcuts plenty strong enough.

 

[Screwdriver]

I'd do as @Dee J suggests but use Unistrut angle to save drilling so many holes....

<edit> and for extra man points, you could tack weld them to make a single bracket.

 

[Phil_D]

Two bits of steel angle back to back look the way to go. Double thickness 'leg' over the roof rack and up and down tabs for the awning. With the hole spacing probably 50mm/2" would do. Bed angle or fence post offcuts plenty strong enough.

What do you mean by bed angle?

 

[Erie Fred]

What do you mean by bed angle?

angle iron from a sleeping bed.
Commonly sourced roadside for easy selection.
I would not recommend it in this application though.

 

[colnerov]

If you don't mind the weight of steel, cut them out of 'I' beam.

 

[Tigman]

If you don't mind the weight of steel, cut them out of 'I' beam.

I'm in favour of this

 

[Dee J]

What do you mean by bed angle?

As has been explained, though it's a bit retro now. From the perimeter frame of sprung frame beds dating from early 20th century. Approx 2"x 2" x 3/16". High grade steel, can be a bit of a ****** to drill, but has a bit of spring to it. Now mostly found lurking in the junk in yards and garages, or supporting the raspberry wires on allotments.

 

[sako243]

Holy moley there's some over engineering going on here as per usual.

I know it's subtly different design but for Pete's sake the winch bumper on my Land Rover is make of 4mm steel and that's taken double the weight of the vehicle and doesn't half get bounced about on the road. The awning on the 110 is held on by two 15x4mm bits of steel bent in an angle but then it's stuck out 6" from the fixing point due to the curve of the roof.