As a fabricator of staino stuff large and small I would love to make stuff like this with nice wood but the price you need to charge would be high.
Getting a shop to do it can be done, CNC fabrication shops are around but again, set up costs are the killer.
Look at architectural fixtures and joins to capture the tubes, they can be very funky designs and worth a look, think industrial supply catalogues.
Another option.. Talked to a roof rack fabricator in the uk and I asked about a 145 roof rack and provided photos and brief dimensions from one of those old catalogues.. his reply:

"Hi, I could make something similar, but there would inevitably be some detail differences, particularly regarding the clamps. Also, the maximum size of parcel I can send is 1.5m so the rack would have to be a little shorter. Price for the rack (powder coated) would be about £230.00, postage is a rather eye-watering £145.00. Regards, Peter"

Not sure why the 1.5 metre restriction. But this option would suite a sedan or coupe ok.

His business:


Example of his work:

..or just strap a pallet to some modern rails. Bit cheaper. Hipster.
^ that looks pretty basic for the money.
You could get it made here.

I found a plastic pallet with cones on the base as feet so upside down looks like a sort of logo brick.
So.
It's got some aluminium extrusion screwed in to enable fixing to my Thule roof bars or even to the car roof rails.
A brick....
That was an example of a rack to suite another make he made. I notice the volvo ones are a bit more interesting/complex. Anyways, i want the real or a dead accurate copy or nothing. I have OCD. Open to a bloody pallet though for a laugh.

Keen to see what that idea of yours looks like! Going to give it a go?
MY lego brick rack needs clamp bolts or 'u' bolts (even cable ties!) to attach to car and it's ready.
I bet it whistles a fine tune, the wind in amongst those cones.... could be interesting....
4 days later
@1971_144GL I'm in Clayton, PM me when you're coming down and I'd be happy to show you!
4 months later
@Samman88 How's that roof rack? It would look good on my 145.

:-P
3 months later
@Samman88 I want your roof rack. Give it to me NOW!
@bigal In the case of me writing off the wagon, I'll bequest it to you. I'll keep an eye out for one in the mean time though!
It's currently taking up space though.
2 months later
If you haven't read my thread yet.. I have a vintage roof rack! These things don't come around all that often it appears. Not the proper 145 rack but this is an old school alloy one in very good condition. Found on Gumtree locally for $200. It curves over the roof perfectly on the Volvo. No idea what it was off, it had been stored for a long time before it was found by the seller.

Won't be fitting it properly until I get some rubber cushioning happening so as not to damage or mark the car.





a year later
@Samman88 written off the wagon yet? I need a 145 roof rack.
Hahaha! I actually have a spare one now that I'm planning on getting chrome plated. I was going to get in contact and ask if you wanted the original one. Send me a PM next time you're in Melbourne/if you'd like me to post it.
Booking ticket to melbourne now! :-)

Wow cool! Thanks. Will PM.
Hey guys.. i’ve just picked up on something about my current roof rack. Look at the pics of my roof rack on my 145 above and then go back to page 1 of this thread and check out the 1st roof rack on the catalogue picture I posted (see part 277949-4). Looks the exact same style. It has the same 5 ribs and the single outer pipe. I always thought the curve fit perfectly over the volvo roof too.

Do I actually have an original old Volvo sedan roof rack?

@Tassie6er @bgpzfm142 @1971_144GL @Samman88 thoughts?
..wait maybe not. Mine has 6 ribs when I look closer.
Your present roof rack looks period correct, but not sure if it's genuine Volvo or not. There were many versions of roof rack made locally back in the day, and importers liked to use local stuff where possible to get their local content tax credits up.
2 years later

They are all here

http://volvo1800pictures.com/document/assessories_71/accessories_1971_group_1.pdf

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