2 hours from a pile of steel to the roof rack, all pressed together at the moment but I'll weld it later today and add some tabs for the solar panel etc
Cross bars under way, I just had to get the flapper disc on the ends of the bars to add a small taper and then smack them together with a rubber mallet. Will drill and plug weld these I think.
Once the cross bars were done I used the drop saw to split them.
And then smacked them on to the main bars with a rubber mallet, I'll weld the split and treat it like a plug weld to attach them to the main bars.
Then I split the end pieces, used a wedge to spread them slightly and pressed them on to the end bars and side bars.
All done, it mounts to my rack frame the using the current cross bar mounts and will replace the bars and basket. The gap at the back is wider to fit a solar panel.
Now to weld and paint (or powder coat)
Cheers
Steve