So after doing Strawberry Pass Trail last week with the Nor Cal gang I dented my rock rails pretty good and decided I needed an upgrade. I like the Boulder Bars a lot but am way to cheap to go out and buy them so I made my own versions. Mine don't stick out as far which I like, but they do stick out enough to easily use a hi lift, use as a small step and will do a much better job of keeping rocks off my doors than my old ones.
I bought 2- 61" long 2"x2" square tubing that is 1/8" thick and cut the ends off with a bandsaw to 45 degree angles and welded on end caps. I chopped the old arms off my old rails and used them again. I like that they are one solid piece and they don't have a plate welded to the end of it that bolts to the frame. I extended them out 4" and then used 1/2" square tubing for side to side reinforcement. I angled them up tight against my rock panels for as much clearance as possible (I know it isn't ground clearance) and left the pinch weld bar attached to keep everything aligned to earlier specs. I ran out of wire for my welder and so wasn't able to finish the second rail but the first turned out great! All I need to do is add the 1/2" reinforcement bars after I pick up more wire, smooth out my grinds and then coat everything with primer and then finally with bedliner. Will post pics of the final product. The 2x2 square tubing cost me $53 and I already had everything else in my garage. Not too shabby I think.
sorry i wasnt even paying attention
I was trying to just pencil in the measurements as I went along but it is going to take for ever so I guess I am going to cheat all the way 