Pluto Roof Rack
Modular sheet metal + aluminum extrusion roof rack solution for the Toyota HiAce.
On top of this "Space Cabin" project, I also helped develop a sheet metal and aluminum extrusion roof rack that fits on all of the HiAce vans, dubbed the "Pluto". The roof racks are available for purchase here.
Type : Vehicle accessory, roof rack
Method : Sheet metal design and manufacturing
Scale : 100+ units sold (Domestic)
Skills used: Fusion 360 sheet metal environment, prototyping, sketching
Project Start
I was brought on to help develop a roof rack system for the Toyota HiAce via Vanlife Northwest. Danny had a clear concept, but was still a bit rough and needed working. It was based on a previous roof rack that he saw and he created some sketches of what he was thinking.
Sketching
After the first meeting and going over the design together, I created some further sketches on the iPad to hone in the function and design variables before taking it into CAD. This step saves a lot of time in the development process.
Attachment point design
Based off the rough measurements we took and found on the vehicle, I was able to design the mechanism we landed on in sheet metal, so it’s easily taken into manufacturing. This assembly was parametric to hone in on the final angle and height.
Side profile design
I then developed the side pieces roughly to see what functionality made sense. The profiles needed to offer variations and modularity to the client, but also wanted some quick attachment function added into the design that would create serious value. I was able to take the side profile design from Fusion and import them into Illustrator and create variations of the design before getting too deep into CAD.
CAD Design
I took the direction from the rough side profile design into CAD and created an assembly. The client had scans from a previous project that allowed us to quickly and easily see where the feet needed to land and the profile that we needed to match. After the side profile was confirmed, I finished off the design with front and rear wind fairings and modeled in the aluminum extrusion to finish off the design. The design was then flattened, drawings were made and sent to a local shop for prototype fabrication.
Production
This first prototype turned out great and with a few adjustments moved into full production. To date, over 100+ units have been sold. With the HiAce being an import, very few solutions if any other are made specifically for this model van. If you’re interested in purchasing your own, head over to HiAce parts and secure your own!
