OK, real quick answers for some of those questions. The main rail design is already set. One off tube bending isn't cheap which is why I order the same design in larger quantities. The new rail design on the Green KJ is just a slight bit different from the original on Ted's jeep, so I can spread the crossbars out a little more forward and back, because the main bars are 1/2" taller than Ted's, mainly to give more room for install the inboard rear mounting bolts. The front and rear bars on Ted's sport rack are about 3/16" from his roof, which is real close when the roof gets warm. When you cut, knotch, fit and weld as much tube as I'm looking at doing, drilling eleventy billion holes in each rack isn't my idea of fun. If you want holes, drill bits are cheaper than my labor rate.
Bugnout, the biggest problem with rails all the way to the front is the big bubble head of a jeep the KJ is. If the rails continue straight forward, there would be a huge funny gap between the rail and the roof. To follow the roof line, several extra bends would be needed, and as already stated, one off tube bending $$$. If I had access to a tube roller it would be easier, but I would need to buy one of those someday ($$$$$$$). So, for now, the main rails will stay in their current design. The basket rack I plan to have a hoop come out from the front bar of the rack to extend more toward the front, but that will make more sense when you see it.
Shipping the HD rails will be fairly cheap and easy. The racks will be fun. The basket rack will have to be collapsible, or shipped by freight. The sport racks if shipped fully welded, just barely squeeze below the max requiments for UPS ground, but they are still an oversize package. Figured shipping yesterday to the east coast (NewYork) for $117. If the rack were shipped so the crossbars could be bolted to the rails, it would cut shipping in half, but the cost of the rack would go up a little due to the extra time and labor to make it collapsible.
Prices:
HD rails with hardware and sandblasted: Regular Retail $270, Sale price for this batch $230. Black Hammered Paint add $15.
Sport Rack with hardware, welded: Reg Retail $475, Sale price for this batch $425. Sandblasting add $25. Painting not available for welded rack.
Sport Rack with hardware, bolt together: Reg Retail $525, Sale price for this batch $475. Sandblasting add $25. Black Hammered Paint add $20.
Basket Rack: no pricing at this time.
I'm putting the tube order in Monday, Sept 3rd. This tube order will consist of the material for me to make the prototype basket rack, and the tubing for all the preorders I receive up to the 3rd. My tube guy will take a few weeks to get them done, so if you can't preorder by the 3rd, you will still have a week or two to get the order in before he actually starts on my order. If you can't do the full amount up front but want in on the first batch, just make a non refundable deposit of $100 on the HD rails or $200 for the Sport rack.
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