need advice from a metal worker/welder

[mtndew]

ok, so here's the scoop. i dont want to pay $500 for a safari rack or tube bumpers so im going to have my ol' lady's dad who is a welder make me one. pretty much what i need to know, is if anyone has some good close up pics of one i can use as a guideline of what i want him to make. second, what are some recomendations for what kind of metal i should use (ie. tube steel or square tube) thickness and all that good stuff. i really dont know what im doing when it comes to that stuff. but again please please someone i need pictures to make this work!!!

[cmays03]

ok what are your plans with the tube bumpers? just for show or are you going to hit things with it? The reason I ask is you can make them out of 1/8 wall tubing so they are light and they will look good. or you can go 1/4 wall which will be heavier but will take more abuse. you can bake them out of anything you want what ever you think looks good. as for pictures you can do a search and find something online that you like and go from there.

[Ole-Boy]

I'm not a welder (so to speak) but I have fabricated quite a bunch of goodies.

Let's think about some basics first.

Size = Figure the size based on the roof area where you'd like it. Keep in mind the measurements of the internal roof/support & cross braces. Calculate that area into the layout for final attachment. As close to you can get (outter edges of roof) where verticle sides meet the top.
Weight = I recommend 1/8" wall aluminum X 3/4" O.D.
Dimensions = Length X Width X 6" overall height. Round pipe will work fine, and easy to bend. I suggest the corners to be bent to 1/4 of an 8" radius.

Where the ends of pipe meet the sides of another, I recommend flattening them with a hammer, or notching them to match the radius of the length they meet with.

Schematic drawing coming soon

Copy/Paste this link into your browser for the bigger picture ---> http://img31.imageshack.us/img31/7176/draftj.jpg

[Ole-Boy]

I realize my drawing is for a roof rack, but it will give you some good views & ideas. Remember, it was a quickie of a drawing too

[mtndew]

cool thanks for the advice. my delima is that the guy im gonna have weld it will only do steel. i know aluminum would be a lot lighter but i actually kinda like the idea of steel because of the way i want him to build the supports, it will double as somewhat of an exo cage. the back supports like the calmini one but with a seperate bar also splitting off and going to quarter panel, and the front running along the side of the windshield, along the fender and down to the bumper and will eventually attach to the bumper im going have him build in the front and the rear.