Steel vs. Aluminum in Off-Road Roof Racks: What’s the Better Choice?

When it comes to building the ultimate off-road rig, the choice of materials matters just as much as the gear you pack. Among adventure travelers, off-road enthusiasts, and 4x4 owners, one debate always sparks discussion: steel vs. aluminum roof racks.

At LFD Off Road, we’ve spent years refining our products for durability, functionality, and adventure-readiness. With our standard off-road roof racks, we offer both carbon steel and stainless steel, known for their unmatched strength and reliability. For select vehicles, we also provide roof racks with extruded aluminum crossbars, but even in those cases, we maintain stainless steel side rails for maximum durability. Why? Because steel consistently proves to be the stronger, more durable choice.

But before you make a decision, let’s look closer at the differences between steel and aluminum and how those differences could impact your off-road adventures.

Weight Savings: Does Aluminum Have an Edge?

The most common assumption is that aluminum is far lighter than steel. While this is technically true, the weight difference isn’t as significant as you might think when it comes to roof racks.

Pound for pound, aluminum is about half the weight of steel, but to achieve the same strength, aluminum often requires more material. Our Extrusion Crossbars, for example, need more material than their steel or stainless steel counterparts, resulting in only a 1.5-pound weight savings per crossbar.

When it comes to the side rails on all-aluminum racks, many competitors use 1/4-inch (0.25") aluminum, while we use 11-gauge (0.12") steel or stainless steel, reinforced with rigidity bends for enhanced structural integrity. This essentially levels the playing field weight-wise.

And keep in mind, on a fully loaded 5,000-pound off-road rig, a weight difference of 10 to 20 pounds would only amount to a fraction of a percent of the total vehicle weight. It won’t significantly impact fuel efficiency, handling, or overall performance.

Bottom line: Aluminum may shave off a few pounds, but the difference is minimal and unlikely to make a measurable impact on your vehicle dynamics.

Strength: Why Steel Stands Stronger

For adventure enthusiasts who demand durability, the tensile strength of steel simply cannot be beaten.

• 304 Stainless Steel: 520–750 MPa tensile strength

• 6061 Aluminum: 290 MPa tensile strength

This means steel is inherently stronger than aluminum and can withstand heavier loads and tougher terrain. To match steel’s strength, aluminum requires thicker material, which offsets the supposed weight advantage and drives up costs.

At LFD Off Road, we ensure all our steel products are engineered not just for strength but for longevity in even the harshest off-road environments. Our commitment to delivering products that last means you’ll be better equipped for whatever your next adventure throws your way.

Bottom line: Steel leads in strength and durability, making it the uncompromising choice for demanding off-road scenarios.

Durability: Built for the Long Haul

Durability is where steel truly sets itself apart. It doesn’t just perform better in the short term; it also outlasts aluminum over time. Here’s why:

• Bending: Steel may bend under pressure, but can be reshaped without significantly affecting its structural integrity. Aluminum, on the other hand, will bend and then break when you try to bend it back.

• Flexing: Under even mild loads, aluminum can flex, which reduces stability.

• Cracking: Over time, hard stress can cause aluminum to crack, especially when subjected to rugged conditions.

• Abrasion Resistance: Steel has better resistance to scratches and punctures. Aluminum is more susceptible to gouging and damage from everyday use.

At LFD Off Road, these factors are why we prioritize carbon steel and stainless steel in our roof rack designs. Even with some racks that include extruded aluminum crossbars, the steel side rails provide the durability needed to maintain structural integrity.

Bottom line: For peace of mind and long-lasting performance, steel is the clear winner in durability.

Compatibility and Aesthetics

One area where aluminum racks often gain favor is compatibility and aesthetics. Many racks on the market today feature extruded aluminum crossbars, with additional equipment and accessories available for this type of construction. Additionally, some customers prefer the sleek, modern look of aluminum.

While we understand the appeal of extruded aluminum, our top priority is always functionality and reliability. That’s why even in racks where we offer extruded aluminum crossbars, we pair them with steel side rails to ensure the rack is built to withstand real off-road conditions.

Bottom line: Aluminum racks blend aesthetic appeal with modern functionality, but at LFD Off Road, we’ll never put aesthetics ahead of performance and durability.

Takeaways: Why Steel Roof Racks are the Better Investment

When it comes down to the grind, steel outperforms aluminum in nearly every category that matters for off-road adventurers:

• Aluminum may save a bit of weight, but the difference is minimal compared to steel’s unmatched strength and durability.

• Steel offers resilience, toughness, and the ability to handle rugged terrain without compromising safety or structural integrity.

• Even in instances where we incorporate aluminum, our steel side rails ensure an unwavering commitment to strength and reliability.

If you’re looking to maximize your rooftop storage (within your vehicle manufacturer’s specifications, of course), we recommend choosing one of our steel roof racks. Whether you opt for carbon steel or stainless steel, you’ll enjoy a product built to last and specifically designed for the challenges of off-road adventures.

Experience the LFD Off Road difference for yourself. Browse our collection of rugged, reliable roof racks and unlock your vehicle’s true potential today!