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expanded metal:
Yes I saw your rust issues with the expanded metal, many reasons why that could happen, like cheap powder coat material or application technique, improper sanding (sandblasting being preferred on steel) skipping steps in heat-to-remove impurities, let cool, heat again, spray, heat again process.... because powder coating should stick for.. very long time. Like with paint, some powder coats are just better.
How has your front bumper held up with powder coating, similar fate to the expanded metal? Both having been in the same environment... down here I was able to drive around with bare metal rack (uncoated) for about a month and pick up very reasonable amount of surface rust (very little). The sanding took it quickly away but sandblasting eliminated all signs of any surface imperfections from rust, mystery imperfections.
blue:
The blue was meant as making the 51" top support extend to 81" top support, in line with the existing 51" line.
I have carried beds, 16 ft tubes and other long things on the roof, and the front would flex in the wind.
Some people carry a lot of stuff, regularly or on some long trips, they cover the whole roof, the equivalent of 81" on Xterra. So one could use the cargo box and have stuff on top of it. Or go crazy on side lights? Or side mount something that fits within 30" or so. Something driver reachable?
shade bars:
I thought of adding some kind of shade/rain cover support with expanding side beams, like pullout arms to support the weight of the canopy. Tube into tube seemed cool, or telescoping round bars
Yes I saw your rust issues with the expanded metal, many reasons why that could happen, like cheap powder coat material or application technique, improper sanding (sandblasting being preferred on steel) skipping steps in heat-to-remove impurities, let cool, heat again, spray, heat again process.... because powder coating should stick for.. very long time. Like with paint, some powder coats are just better.
How has your front bumper held up with powder coating, similar fate to the expanded metal? Both having been in the same environment... down here I was able to drive around with bare metal rack (uncoated) for about a month and pick up very reasonable amount of surface rust (very little). The sanding took it quickly away but sandblasting eliminated all signs of any surface imperfections from rust, mystery imperfections.
blue:
The blue was meant as making the 51" top support extend to 81" top support, in line with the existing 51" line.
I have carried beds, 16 ft tubes and other long things on the roof, and the front would flex in the wind.
Some people carry a lot of stuff, regularly or on some long trips, they cover the whole roof, the equivalent of 81" on Xterra. So one could use the cargo box and have stuff on top of it. Or go crazy on side lights? Or side mount something that fits within 30" or so. Something driver reachable?
shade bars:
I thought of adding some kind of shade/rain cover support with expanding side beams, like pullout arms to support the weight of the canopy. Tube into tube seemed cool, or telescoping round bars
So basically a DepHep but aluminum...? It is pretty awesome. If I didn't have my DepHep already I would totally be in for this. I don't carry much in my basket, and when I do it is not hundreds of pounds. I think this would satisfy 100% of what I have carried up there so far. The light weight and rust-resistance would be much preferred.
I'm trying to think of a use case for the blue & green to the front of the roof. The green could obviously have lights attached to it. Maybe you angle the blue part down to follow the wetbox lines and have low-profile roof light mount. But what could you put across/carry on the blue lines? Of course I would love to still be able to open the wetbox, but have that be usable roof rack space as well. Maybe that is not possible though. IDK what I might carry in that spot realistically.
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