Re: Homebrew Con-Ferr Style Porthole Roof Rack Build
Posted: Sat Dec 10, 2011 4:09 pm
Today I smoothed out the bending die and bent up some test corners:
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/1E95AD25.jpg)
Round corner comparison to original Con-Ferr rack:
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/561C5432-orig.jpg)
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/8E655D60-orig.jpg)
Two 45deg bends separated by 12":
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/2A483DD1-orig.jpg)
Two 45deg bends separated by 8":
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/9BDBC159-orig.jpg)
I like both the round corner and 8" separated bends. I think I'm leaning more towards the two 45deg bends though. I like that it looks modern, that there is exactly 6" of straight length between the bends (which is the same as the porthole plate sections) and that the steel will be easy to form and tack down around the gentler bends. I also like that I can weld a small tab on that corner and mount an offroad light there without it protruding from the rack width. I think the 90deg round corners will look too pointy, like a tiara on top of my pavement princess (FY ..i.. ).
Now I think I need to bend another 2x45deg section and weld a corner piece to it. I need to be sure I like how it looks before I bend up all this steel I have laying here. I also need to figure out how I'm going to bend up the 10' lengths to make a rack the size I need. I'll probably do front and back pieces like this [ ] and then weld in straight bars for the sides. I know I will waste at least one tube trying to get the width right. I always seem to F that up when bending U shaped conduit.
Now I'm off to bend up another corner and try out my conduit punch.....
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/1E95AD25.jpg)
Round corner comparison to original Con-Ferr rack:
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/561C5432-orig.jpg)
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/8E655D60-orig.jpg)
Two 45deg bends separated by 12":
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/2A483DD1-orig.jpg)
Two 45deg bends separated by 8":
![Image](http://i263.photobucket.com/albums/ii145/jackbinthebox/Snapbucket/9BDBC159-orig.jpg)
I like both the round corner and 8" separated bends. I think I'm leaning more towards the two 45deg bends though. I like that it looks modern, that there is exactly 6" of straight length between the bends (which is the same as the porthole plate sections) and that the steel will be easy to form and tack down around the gentler bends. I also like that I can weld a small tab on that corner and mount an offroad light there without it protruding from the rack width. I think the 90deg round corners will look too pointy, like a tiara on top of my pavement princess (FY ..i.. ).
![big grin :D](./images/smilies/icon_mrgreen.gif)
Now I think I need to bend another 2x45deg section and weld a corner piece to it. I need to be sure I like how it looks before I bend up all this steel I have laying here. I also need to figure out how I'm going to bend up the 10' lengths to make a rack the size I need. I'll probably do front and back pieces like this [ ] and then weld in straight bars for the sides. I know I will waste at least one tube trying to get the width right. I always seem to F that up when bending U shaped conduit.
Now I'm off to bend up another corner and try out my conduit punch.....