Builds Fly By Night (11 Viewers)

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Where the fender-lip measures out

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Been thinking for weeks now about how I want to go about doing the new inner roof support/roof-rack mounting without being a total plagiarist. For the mounting of the apparatus, I came up with three possible ideas.
First, (1) like what @scrapdaddy did, fab up some mounts with captured nuts and weld them along the inner upper roof rails and go from there.
Also thought about (2) just welding nuts to some 1/8” or 3/16” plate and either cutting out sections along the rail to weld them in flush or weld them on top of the sheet metal by cutting holes with a hole saw where the captured nuts can be recessed.
Third idea (3) was to rip a ~7’9” section of 2” x .120” wall square tubing to a depth of 3/4”, weld nuts to it in the desired locations and weld the whole shebang(s) along the roof rails. In theory, this would make that whole area very slick and clean, but would also add 20 - 30 lbs. to the already top-heavy roof area.
Idea 2 would also be pretty clean, but require more work, especially if trying to flush mount. Thought briefly about utilizing the stock 6mm roof support mount holes, but those small bolts just don’t inspire confidence.

So, in conclusion, and in trying to find the best all around solution, I fall back to idea #1, pioneered by those who have gone this road before.

Here’s some progress pics...

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