The correct dies for the Hossfeld bender finally showed up and I put them to use.
The goal of the 2nd version of this rack is to build a rack that looks good, works even better, and still remains fairly light weight for the 4Runner.
I ordered some thiner wall tubing for this rack. The .083 wall thickness tubing on the first version is super strong, but it ended up being a little heavy for a small truck. This design also uses bent corners rather than the formed plates.
This rack uses a mix of .065 wall thickness and .083 in high stress areas.
The rack will hold four lights up front, two wide beam and two pencil beam.
Another view. I was just mocking up a few things to check the design lines before I stared cutting up more metal.
More to come...
Cheers,
tp