Custom Roof Rack Project for Bronco Sport Badlands 2025 / Design and Fabrication in Argentina

[Timon.Arg]

Hi everyone,

I wanted to share a roof rack project I’m currently developing for my Bronco Sport Badlands here in Argentina.

The general idea is to build a custom roof rack inspired by the Rough Country roof rack for the Bronco Sport. Since importing one of these racks to Argentina is not simple or cost-effective, I decided to work on a locally fabricated version, designed around the same general concept: a low-profile rack, made mostly from folded sheet metal, with side panels, cross members, and integrating lights and accessories.

Reference: Rough Country - Roof Rack for Ford Bronco Sport 2021-2026 LINK

I downloaded a 3D model of the Bronco Sport and I’m working with a friend on the CAD development. At this stage, we are defining the side plates, front and rear geometry, folded sheet-metal structure, mounting strategy, and accessory integration.

Reference model: 3D model LINK (Other models I downloaded don't match the measurements of the actual vehicle; this one looks VERY realistic.)

One of the main design decisions right now is how to mount the rack to the vehicle.

The simplest option would be to clamp or mount it over the factory longitudinal roof rails. That would avoid modifying the vehicle and would keep everything relatively reversible. However, that option also reduces the available space between the roof and the rack, which is important for routing wiring, placing lights, and integrating accessories cleanly.

Because of that, we are considering removing the factory roof rails and using the original mounting points or a more direct mounting solution. I found the Ford Performance roof-mounted LED light bar installation manual (attached M-15200K-CXR.pdf) useful as a reference, since it shows the interior disassembly required to access the roof rail mounting nuts, as well as the wiring route through the A-pillar and roof area. This gives us a better understanding of what is involved before deciding whether this route makes sense.

The goal is not only to make the rack look good, but also to make it functional, structurally sound, serviceable, and as clean as possible in terms of wiring and accessory mounting.

At this point, the project is still in the design stage. I’ll keep posting updates as we move forward with the CAD model, prototype parts, folding details, mounting brackets, and eventual installation on the vehicle.

I am attaching a few images of the reference rack and the current CAD progress so you can see where the project is heading.

Any comments, suggestions, warnings, or experiences from people who have removed the roof rails, installed roof-mounted light bars, fabricated racks would be very welcome.

I’m especially interested in feedback regarding:

• Factory roof rail removal
• Possible water sealing issues
• Safe routing of wiring near the curtain airbags
• Rack mounting points
• Wind noise

Thanks in advance for any input.
I will share information as the project progresses.

 

[RidingTheBronco]

Hi everyone,

I wanted to share a roof rack project I’m currently developing for my Bronco Sport Badlands here in Argentina.

The general idea is to build a custom roof rack inspired by the Rough Country roof rack for the Bronco Sport. Since importing one of these racks to Argentina is not simple or cost-effective, I decided to work on a locally fabricated version, designed around the same general concept: a low-profile rack, made mostly from folded sheet metal, with side panels, cross members, and integrating lights and accessories.

Reference: Rough Country - Roof Rack for Ford Bronco Sport 2021-2026 LINK

I downloaded a 3D model of the Bronco Sport and I’m working with a friend on the CAD development. At this stage, we are defining the side plates, front and rear geometry, folded sheet-metal structure, mounting strategy, and accessory integration.

Reference model: 3D model LINK (Other models I downloaded don't match the measurements of the actual vehicle; this one looks VERY realistic.)

One of the main design decisions right now is how to mount the rack to the vehicle.

The simplest option would be to clamp or mount it over the factory longitudinal roof rails. That would avoid modifying the vehicle and would keep everything relatively reversible. However, that option also reduces the available space between the roof and the rack, which is important for routing wiring, placing lights, and integrating accessories cleanly.

Because of that, we are considering removing the factory roof rails and using the original mounting points or a more direct mounting solution. I found the Ford Performance roof-mounted LED light bar installation manual (attached M-15200K-CXR.pdf) useful as a reference, since it shows the interior disassembly required to access the roof rail mounting nuts, as well as the wiring route through the A-pillar and roof area. This gives us a better understanding of what is involved before deciding whether this route makes sense.

The goal is not only to make the rack look good, but also to make it functional, structurally sound, serviceable, and as clean as possible in terms of wiring and accessory mounting.

At this point, the project is still in the design stage. I’ll keep posting updates as we move forward with the CAD model, prototype parts, folding details, mounting brackets, and eventual installation on the vehicle.

I am attaching a few images of the reference rack and the current CAD progress so you can see where the project is heading.

Any comments, suggestions, warnings, or experiences from people who have removed the roof rails, installed roof-mounted light bars, fabricated racks would be very welcome.

I’m especially interested in feedback regarding:

• Factory roof rail removal
• Possible water sealing issues
• Safe routing of wiring near the curtain airbags
• Rack mounting points
• Wind noise

Thanks in advance for any input.
I will share information as the project progresses.

Hi, cool project. I love the 3d model and file sharing software.

I have a roof rack on my BS (not pictured). I like it mostly. But there are some struggle points.
I wish...
It were easier to load
I could more easily clean the painted surface below it.
The rack itself, with so many texture changes, bends and nuances were much easier to clean
...
Which leads to my main dream....to make it easily removable. I have often though about how i could use the factory rails to make a rolling and loading system. I dream of rolling my whole rack off the back of the vehicle.. Surely this would be for cleaning and maybe even for loading.

Yes, lights are cool, but not having the roof rust through would be even cooler.

 

[PHRIOS]

Hello Hermano!!!

Here in Brazil, many people encounter the same type of problem. We can't bring anything from abroad because the price makes any purchase from the US unfeasible.

However, we have a solid community that is growing quite a lot. That's why we use the same method as you. We have to create...

But I don't remember doing it on a roof rack, but rather adapting the roof bars that already come with the vehicle. Now we've seen many underbody protection systems where people have developed the project and are already selling them.

If you're interested, I can send you the links.

Saludos dede Brasil

 

[Timon.Arg]

Hello Hermano!!!

Here in Brazil, many people encounter the same type of problem. We can't bring anything from abroad because the price makes any purchase from the US unfeasible.

However, we have a solid community that is growing quite a lot. That's why we use the same method as you. We have to create...

But I don't remember doing it on a roof rack, but rather adapting the roof bars that already come with the vehicle. Now we've seen many underbody protection systems where people have developed the project and are already selling them.

If you're interested, I can send you the links.

Saludos dede Brasil

Hi hermano!

Thanks for your message. I completely understand the situation, here in Argentina we have the same problem. Importing parts from the US usually becomes very expensive, sometimes almost unreasonable, so developing local solutions ends up being the only realistic option.

That is exactly the idea behind this project: not only to build a roof rack for my Bronco Sport, but also to explore whether a locally fabricated design could make sense for other owners in the region.

I’d definitely be interested in seeing the links. Even if they are not roof rack projects specifically, underbody protection systems, local fabrication solutions, and accessory mounting ideas can be very useful references. [Talvez isso justifique uma viagem ao Brasil para comprar alguma coisa. haha]

Saudações da Argentina!

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