I like it a lot. If you aren't going to use all that space, then its too big, I personaly cary a bunch of people and a lot of gear, so that wouldn't be too big for me. I like it!

 

Ok, Is it just me or is there a dismissal of the dangers of Welding EMT Conduit. This stuff is galvanized folks. Metal Fume Fever is the absolute most dangerous with Galvanized Steel. I know I just got a pretty bad case of zinc/cadium poisoning from welding my roof rack 3/4" EMT, I even grinded the ends I was welding for the most I had heard about it on a few boards was to grind the ends for better welds, nothing about the dangers (and I had just started it.) the next weekend I had a mask, fan blowing debris and all the doors in the garage open.

BTW it looks pretty good and nice bends buddy, I just hope you had great ventilation and a mask... I felt very fluish, aching, coughing and a major headache for 5 days after, I am still coughing.

 

TXCherokee
No.. there was no dismissal of safety, atleast on my part. I ASSuMEd that we were all adults and all had a fair amount of common sense. I really didn't feel the need to say that I did all my welding/grinding in front of that big opened roll-up door with a mask on(most of the time). I also did have a fan blowing some but not too much to mess with Argon flow(TIG Weld). I keep my kids and pets out of the shop when I'm working for their safety and mine. But the nosey kids and pets across the street maybe seeing spots for a while .

I've been a Machinist/Tool-Moldmaker for the last 17 years. There hasn't been too many different types of metals that I haven't Machined, Welded, Cut, Ground,...... from Aluminum, Beryllium Copper to Titanium so I know all about the different inhalation problems with various metals.

Got laid-off like so many before me and I now work at a hospital as a Plant Engineer. But I still do machining work at home/shop cause I just love it so much and it pays pretty good when you have work.

James L.

 

I case anyone is following this rack build, I will get back on it after the first of the year. Both my kids are out of school for the holidays until Jan 4 '10, so I spending alot of time with them and none in the shop. Still have to finish welding and a coat of paint on it.

I hope everyone has a great Christmas, James L.

 

That is a great looking rack, the best thing about building it yourself is you make it whatever size you want. If you think it might be to big now. look down the road a little when you might have more gear than you do now. Its deffinetly better to make it bigger than you need it at the time you build it. Pics of mine are in my album, but when i built mine i had the intentions in the future to only put a spare, hi lift and shovel up there. Hopefully this made a little sense.
Great job again
Rusty

 

sounds good

 

This is the best rack i've seen on an XJ. I love how it fills the entire roof of the car.