Cone Engineering offers a vast range of exhaust components and fabricated automotive parts in various sizes from materials like stainless steel and mild steel. Instead of off-the-shelf completed exhaust systems, we manufacture high-quality components that allow you to design and fabricate your own products that set you apart. You’ll be able to find what you need for your vehicle, and you won’t be stuck with the same standard parts everyone else has.
One of the unique automotive components we’ve developed for a customer is an overland roof rack. An overland roof rack comes in rack, rail, or cross-bar form and provides the vehicle with extra storage space for kayaks, fishing rods, rooftop tents, and other outdoor gear. The following case study illustrates how Cone Engineering created an overland roof rack specifically for the Ford Bronco Sport.
The Challenge
Tasked with delivering an overland roof rack for the Bronco Sport, Cone Engineering needed to design and engineer a roof rack that could mount to the factory stock vehicle without drilling into or damaging the body. The overland roof rack would have lightweight and aerodynamic specifications, the ability to withstand loads over 600 lbs, and a style that matched the vehicle’s aesthetics.
Cone Engineering designed an overland roof rack for the Bronco Sport that met the client’s budget and functional specifications. Our advanced laser cutting and bending capabilities allowed us to provide the fastest lead possible times.
The Solution
We leveraged the following services to deliver the client’s solution:
- 3D modeling and design
- Bending
- Laser cutting
- Forming
- Welding
- Chamfering
- Finishing
Our CAD modeling and design expertise helped us refine the overland roof rack to meet the client’s aesthetic and operational specifications. The majority of the project required our laser cutting and bending capabilities, which provided the client with rapid lead times. Using 5052-H32 aluminum and A36 mild steel materials, we fabricated the product with tight tolerances (±0.010”). To finish, we applied the black textured powder coating that the client requested.
The Result
We delivered the client’s product within a 4-week turnaround time, and we now produce over 100 units per year. The client has not received any returned products due to our exceptional quality and rigorous testing under extreme conditions. In fact, the customer has expressed interest in expanding into new product lines with the help of our capabilities and expertise.
Want to Work With Us on Your Automotive Project?
This case study demonstrates Cone Engineering’s ability to meet challenging requirements with innovative application engineering capabilities. We were able to meet all budgetary and performance specifications with a quick turnaround, resulting in a satisfied repeat customer for whom we now produce more than 100 overland roof rack units per year.
Cone Engineering can custom design and engineer unique solutions for your automotive project. Contact us to speak with a team member about your needs.