RVStow Roof Rack Cargo Basket DIY Lightweight Mod: Cut Weight Without Sacrificing Storage
The RVStow Roof Rack Cargo Basket is a rugged, all-metal storage solution designed for overlanding and RV travel, but its factory weight can add up when every kilogram counts. This article explores a DIY lightweight modification that strips excess mass from the basket while preserving its structural integrity and cargo capacity. By selectively removing non-essential steel and replacing hardware with aluminum components, you can reduce the basket’s weight by up to 10 pounds (4.5 kg) without compromising security or weather resistance. This mod is ideal for owners who prioritize fuel efficiency, payload capacity, or easier mounting on lightweight roof racks.
What Is the Default Weight of the RVStow Roof Rack Cargo Basket, and Why Does It Matter?
The RVStow Roof Rack Cargo Basket ships at approximately 35 pounds (15.9 kg) for the standard 60-inch x 40-inch model. While this is competitive among steel wire baskets, it still represents a significant addition to your RV’s roof load, especially when combined with a roof rack system, crossbars, and cargo. Every extra 10 pounds on the roof reduces fuel economy by roughly 1% to 2% on average, according to industry tests. For long-haul travelers, this translates into tangible fuel cost savings over time. Additionally, many RV roof racks have weight limits between 150 and 200 pounds, so cutting 10 pounds from the basket frees up capacity for heavier gear like solar panels or water jugs.
This mod focuses on three areas: the basket’s floor mesh, side rails, and mounting hardware. The factory floor uses heavy-duty expanded steel mesh that is over-engineered for most cargo loads. By swapping to a lighter perforated aluminum sheet or cutting away unneeded reinforcement bars, you can drop significant weight. Similarly, replacing steel U-bolts with stainless steel or aluminum versions reduces mass at the attachment points. The result is a basket that sits lighter on your roof, places less stress on crossbars, and improves aerodynamic efficiency.
What Tools and Materials Do You Need for the DIY Lightweight Mod?
Before starting, gather the following tools and materials. Most are available at local hardware stores or online retailers. Total cost for the mod should range between $30 and $60 USD, depending on whether you repurpose existing hardware.
| Item | Specification/Quantity | Approximate Cost (USD) |
|---|---|---|
| Perforated aluminum sheet (1/8-inch thick) | 60″ x 40″ (to replace floor mesh) | $25–$35 |
| Aluminum U-bolts (3/8-inch diameter) | 4–6 units (to replace steel originals) | $10–$15 |
| Angle grinder with cutting wheel | 1 for cutting steel mesh and bars | Already own (~$15 rental) |
| Drill with titanium bits | For pilot holes in aluminum sheet | Already own |
| Stainless steel rivets (3/16-inch) | 20–30 rivets (to secure sheet) | $5 |
| Safety gloves and eye protection | 1 pair each | $10 |
If your basketry has a pre-drilled floor, you may skip the rivet step and reuse existing holes. For models with welded mesh, you must cut the factory steel floor and attach the aluminum sheet using rivets or self-tapping screws.
Step-by-Step: How to Remove the Factory Steel Floor and Replace It With Aluminum
Start by removing the basket from your RV and placing it on a flat work surface. Use a marker to outline where the existing steel mesh is welded to the frame. On most RVStow baskets, the floor is welded at 12 to 16 points along the perimeter. Use an angle grinder with a cutting wheel to sever these welds safely. Wear protective gear and work in a ventilated area. Once the steel mesh is free, lift it out and set aside (or recycle). Clean the frame edges with a wire brush to remove slag and burrs.
Next, measure the inner dimensions of the basket frame. For the standard 60×40 model, the internal opening is roughly 58 inches by 38 inches. Cut the perforated aluminum sheet to these dimensions using a reciprocating saw or jigsaw with a metal blade. Debur the edges with a file. Place the sheet inside the frame, aligning it so that it sits flush with the bottom of the side rails. Drill pilot holes every 6 inches along the perimeter, then secure the sheet using stainless steel rivets. For extra rigidity, add two cross-members using leftover aluminum strips (1-inch wide). This floor now weighs about 4 pounds versus the original steel mesh at 12 pounds—an 8-pound savings.
If the basket has a center reinforcement bar that is welded to the floor, you can cut it out as well. Many RVStow baskets include a longitudinal bar that adds stiffness but is unnecessary once the aluminum sheet is installed. Grind away the welds and remove the bar. This yields an additional 2 to 3 pounds of weight reduction.
How to Replace Steel U-Bolts With Aluminum Versions for Further Weight Savings
The factory mounting hardware on the RVStow basket uses steel U-bolts that typically weigh about 0.5 pounds each. Replacing them with 3/8-inch aluminum U-bolts reduces that to 0.2 pounds per bolt. For a basket with four mounting points, that’s a savings of 1.2 pounds. If your basket uses six bolts (common for larger models), you save almost 2 pounds. Aluminum U-bolts are available at marine supply stores or online for around $3 each. Ensure they are rated for the load—check that the “proof load” matches or exceeds the original steel bolts. Most aluminum U-bolts with a tensile strength of 10,000 PSI are adequate for cargo baskets rated under 150 pounds cargo capacity.
Installation is straightforward: remove the steel U-bolts from the basket’s mounting brackets, slide the aluminum replacements in place, and tighten with nylon lock nuts. Avoid over-torquing, as aluminum threads can strip more easily than steel. A torque wrench set to 10–12 ft-lbs is recommended. This mod also reduces corrosion risk, as aluminum does not rust like steel. For enhanced security, pair with a lock upgrade from our guide on RVStow Roof Rack Cargo Basket Lock Security Upgrade.
What Are the Structural Integrity and Safety Considerations for This Mod?
While cutting weight is beneficial, you must not sacrifice safety. The RVStow basket’s steel frame is engineered to handle dynamic loads during travel—including wind lift, vibration, and sudden braking. The DIY lightweight mod should only affect the floor and hardware, not the perimeter rails. The perimeter rails remain steel and provide primary structural support. The aluminum floor, though lighter, is less rigid than steel. To compensate, add two cross-straps or webbing tensioners (not included in the mod) that cinch down cargo to prevent shifting. Do not exceed the basket’s original load rating (typically 150 pounds). The mod reduces net weight of the basket but does not increase structural capacity.
Also consider wind dynamics: a lighter basket may be more susceptible to wind lift at highway speeds. Installing a wind deflector can mitigate this. See our guide on RVStow Roof Rack Cargo Basket Noise Reduction & Wind Deflector Solutions for compatible options. Additionally, the aluminum floor may have a different coefficient of thermal expansion than steel, so ensure rivet holes are slightly oversized (1/32-inch) to allow for expansion without cracking. Regular inspections every six months are recommended to check for loose rivets or deformation.
What Owners Say About This Lightweight Mod
Feedback from the RVStow owner community is generally positive. On forum boards and YouTube comments, users report an average weight reduction of 8 to 12 pounds. One owner stated, “I dropped 9.5 pounds from my basket using the aluminum floor swap, and I noticed a 1.5 mph increase in fuel efficiency on my diesel pusher.” Another noted, “The basket feels just as sturdy when carrying two kayaks. The aluminum sheet is strong enough for my needs.” A common caution is about noise: the aluminum floor can produce a higher-pitched hum at highway speeds compared to the dampened steel mesh. This is easily addressed with a rubber mat or a wind deflector, detailed in our RVStow Roof Rack Cargo Basket Wind Deflector Installation & Performance Test article. Some owners also recommend sealing the aluminum edges with silicone to prevent galvanic corrosion between dissimilar metals. Overall, the mod is rated 4.5 out of 5 stars in community polls for balance of weight savings versus cost and effort.
Frequently Asked Questions
Q1: Does this modification void the RVStow warranty?
A: Yes, typically any alteration to the basket structure (including cutting welds) voids the factory warranty. However, the warranty period on RVStow baskets is usually 1 to 2 years, so many owners perform the mod after this period. Check your manufacturer’s policy.
Q2: Can I use a steel sheet instead of aluminum to save weight?
A: No, steel is about three times denser than aluminum. Using a thinner steel sheet might save some weight but not nearly as much as aluminum. Aluminum’s weight-to-strength ratio is optimal for this application.
Q3: Will the aluminum floor corrode in salt spray or coastal environments?
A: Aluminum naturally forms an oxide layer that resists corrosion, but it can pit in marine environments if not protected. For longevity in salt air, consider a clear powder coat or anodizing. Our RVStow Roof Rack Cargo Basket Corrosion Resistance & Salt Spray Test covers compatible coatings.
Q4: How much time should I budget for this DIY mod?
A: Expect 3 to 5 hours for a first-time attempt, including cutting, drilling, and riveting. Experienced fabricators can finish in 2 to 3 hours.
Q5: Can I mount a solar panel on the modified basket?
A: Yes, but you may need to reinforce the aluminum floor with crossbars to support the panel’s weight. See our guide on RVStow Roof Rack Cargo Basket Solar Panel Mounting Compatibility for load limits and mounting brackets.
Q6: Will this mod affect wind noise or drag?
A: It can reduce overall weight-induced drag, but the open aluminum floor may create slight turbulence. Using an aerodynamic fairing can smooth airflow. Check out our Aerodynamic Fairing Installation for RVStow Roof Rack Cargo Basket: Reduce Drag & Noise for installation tips.
