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Old 11-09-2012, 12:25 PM
CumberlandXstar CumberlandXstar is offline
TT Enthusiast
Join Date: Feb 2012
Boat: Mastercraft X-Star 2004 MCX
Location: Midwest
Posts: 167
Custom X Star Bimini/Cargo Rack

I am starting to build a custom bimini/cargo rack for my 2004 X-Star. I bought the boat as a left over model back in Spring of 2005. Put a ton of fun hours on it with family and friends and now me and my wife a prepping for our first child in January. The boat did not come with a bimini top and I never felt like we needed one because we have a houseboat and are not in the boat all day long so we enjoy the sun. Now we will need some shade so along comes a bimini. The boat can get crowded with boards so I always wanted more racks so why not build a cargo rack style bimini. I also figured I might as well mimic the picklefork on the front of my boat.

Here is the reference marks that I used to measure the tower

Here is my super extensive rendering of what look I am going for. Lots will change but this is the overall direction I am looking to go.

I have a tubing bender but when out and bought a tubing roller because I think that the over all look of rolled tubing looks really good. It turns out the one tool Harbor Freight makes that works well is the tubing roller that comes with 1" , 1.5" and 2" roller dies.

I ordered up 1/16" and 1/8" wall 6061 1" DOM Aluminum to roll some test pieces. And it worked great in both thicknesses. The rolls were very smooth and did not deform the aluminum at all. I decided to go with the 1/8" thickness for strength especially with the extra weight from carrying the boards.

Here is my rough layout of the tower and where the cargo rack will be.

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