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  #1  
Old 11-09-2012, 12:25 PM
CumberlandXstar CumberlandXstar is offline
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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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  #2  
Old 11-09-2012, 03:30 PM
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XStar08 XStar08 is offline
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Nice project. Try to get an idea of how the piping is made on the original biminis. There is more than one that connects the bimini with the tower. Guess you will need also somethig that keeps the bimini in place when on speed (force from below, wind).
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  #3  
Old 11-09-2012, 04:18 PM
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willyt willyt is offline
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you really should just make bill really, really happy and buy a 2013. Let me know if you want any help with this buddy, its been too long
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  #4  
Old 11-09-2012, 09:52 PM
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MASTIQUE MASTIQUE is offline
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  #5  
Old 11-13-2012, 07:49 PM
CumberlandXstar CumberlandXstar is offline
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I laid out the outer structure with steel electrical conduit and held the shape up to the boat to see how I liked it. Looks pretty good and I am happy enough with the shape to keep going with it. I will post up some pictures tomorrow to show the progress.

Last edited by CumberlandXstar; 11-14-2012 at 12:28 PM.
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  #6  
Old 11-14-2012, 02:00 PM
CumberlandXstar CumberlandXstar is offline
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I propped it up to get an idea of how its going to look.



Here are the clevis that I am going to use on the rolled strut to support the front of the bimini.

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  #7  
Old 11-14-2012, 02:42 PM
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76S&S 76S&S is offline
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Nice project!
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  #8  
Old 11-14-2012, 05:15 PM
CumberlandXstar CumberlandXstar is offline
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Here are a few more pictures. I wish it would cover a little more than it does, but I want to keep the picklefork looking proportional unlike the others that have been done.









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  #9  
Old 11-14-2012, 05:41 PM
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BrooksfamX2 BrooksfamX2 is offline
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Lookin good so far...........
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  #10  
Old 11-15-2012, 06:09 PM
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Dang... that is going to look awsome.
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