Ski rack bill of materials
From DDL Wiki
Bill of Materials
| Assembly | Part | Quantity | Description | Material | Manufacturing process | Weight [grams] | Image |
|---|---|---|---|---|---|---|---|
| 1. Mounting Bracket | 4 | Mounts carrier to roof rack. | 
| ||||
| 1A. Base Screw | 1 | Connects bracket to rack. | Steel | Cold Heading and Thread Rolling | 6 | 
| |
| 1B. Slider Top | 1 | Connects the bails to the lower horizontal cross bar. | Molded Plastic | Injection Molding | 36 | 
| |
| 1C. Short Bail Screw | 2 | Holds the bails together | Steel | Cold Heading and Thread Rolling | 6 | 
| |
| 1D. Long Bail Screw | 2 | Holds the bails together | Steel | Cold Heading and Thread Rolling | 9 |
| |
| 1E. Upper Bail | 1 | Clamps over roof rack cross bar. | Molded Plastic | Injection Molding | 45 | 
| |
| 1F. Square Nut | 1 | Provides purchase for the base screw withing the slider top. | Brass | Forging and tapping | 5 | 
| |
| 1G. Rubber Pad | 1 | Provides grip to the bails. | Rubber | Casting | 13 | 
| |
| 1H. Lower Bail | 1 | Clamps under roof rack cross bar. | Molded Plastic | Injection Molding | 49 | 
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| 1I. Hex Nut | 1 | Provides purchase for the bail screws within the lower bail. | Brass | Forging and tapping | 5 | 
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| 2. Hex Key | 2 | Attaches the ski lift to the ski rack. | |||||
| 2A. Hex Key | 1 | Holds the ski lift in place. | Molded Plastic | Injection Molding | 6 | 
| |
| 2B. Hex Nut | 1 | Provides purchase for the bold within the hex key. | Brass | Forging and tapping | 5 |
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| 2C. Bolt | 1 | Connects with the hex key through the ski lift to attached the ski lift | Steel | Cold Heading and Thread Rolling | 12 | 
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| 3. Ski Lift | 2 | 
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| 3A. Ski Lift | 1 | Raises up rack to provided additional clearance. | Molded Plastic | Injection Molding | 25 | 
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| 3B. Hex Nut | 1 | Press fits into ski lift to provide secure purchase for mounting screws. | Brass | Forging and tapping | 5 |
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| 3C. Button Head Screw | 1 | Holds ski lift together. | Steel | Cold Heading and Thread Rolling | 11 |
| |
| 4. Lock Assembly | 2 | ||||||
| 4A. Lock Housing | 1 | Holds lock in place within release lever. | Steel | Casting | 
| ||
| 4B. Lock | 1 | Preassembled lock. | Steel | Unknown multi-part assembly process. | 10 | 
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| 4C. Lock Cap | 1 | Replaces optional lock | Molded Plastic | Injection Molding | 0 | 
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| 5. Carrier Bottom | 2 | ||||||
| 5A. Rivet | 3 | Holds rack together | Aluminum | 0 | 
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| 5B. Hinge Spring | 1 | Opens rack. | Brass | Coiling | 15 | 
| |
| 5C. Lower Compression Pad | 1 | Compresses to firmly hold skis in place | Rubber | Extrusion | 137 | 
| |
| 5D. Bottom Shell | 1 | Holds bottom compression pad in place. Mounts to mounting brackets. | Steel | Extrusion | 198 | 
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| 5E. Latch (Bottom Half) | 1 | Provides something for upper half of latch to secure to. | Molded Plastic | Injection Molding | 20 | 
| |
| 6. Latch | 2 | 
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| 6A. Latch Housing | 1 | Contains the latch mechanisms. | Molded Plastic | Injection Molding | 52 | 
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| 6B. Release Lever | 1 | Releases the latch when pressed. | Molded Plastic | Injection Molding | 45 | 
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| 6C. Lock Back | 1 | Interfaces between the lock and locking tab. | Steel | Casting | 5 | 
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| 6D. Locking Tab | 1 | Rotates when rack is locked to hold the rack shut. | Steel | Punching | 0 | 
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| 6E. Spring | 1 | Returns the latch release lever to its closed position | Brass | Coiling | 4 | 
| |
| 6F. Lock Washer | 1 | Holds the locking mechanism together. | Steel | 0 | Missing | ||
| 7. Carrier Top | 2 | 
| |||||
| 7A. Upper Horizontal Shell | 1 | Holds the rubber compression pad in place. | Rubber | Extrusion | 206 | 
| |
| 7B. Upper Compression Pad | 1 | Compression pad to hold the skis firmly in place | Rubber | Extrusion | 127 | 
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| 7C. Rivet | 2 | Aluminum | 0 |
| |||
| 7D. Hinge Shell | 1 | Connects the top and bottom parts together and acts as a hinge. | Molded Plastic | Injection Molding | 67 | 
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