I'm in the process of designing and having fabricated a roll cage compatible foot that clamps onto the roll cage that is specific to Front Runner Racks. All built in Solidworks and I am about to have the clamps machined and test fitted. After extensive research I found that no wide clamps exists, particularly not out of aluminum. Does anyone here have access to a CNC and would be willing to help machining the clamps? I have quoted several local options. All doable just crazy expensive.
Thanks. I got 4 local quotes and settled on a place that is one of the more affordable ones as well as close by. I'm just surprised that no one makes aluminum roll bar clamps in different widths.
Progress update. Clamps are done and I am test fitting them now. Ran into a snag though. There are two bumps on the inside of the NAS 90 cage near the joint where the front meets the rear above driver and passenger window. Any idea what these are and what happens when I grind them off? I need to grind them off in order to have the cage clamp fit correctly.
Legs came out great! Of curiosity, which stock gutter legs are you using - the low or the high? BTW, you have enough support on that rack to put another 90 on top of it! :grin
I got the 245MM legs as I wanted more than 1" of clearance from the roof so that I can fully open the sun roof and also be able to get a hand in there to wipe the roof off.
Dropping the legs off for powder coating this week.
I realized a potential flaw with my design. The clamps are aluminum and the bolts are stainless. This will eventually cause galvanic corrosion, right? Is there anything I can do to prevent this?
Definitely. They'll actually work better on a full cage than a half cage. Going through the process I learned that the half cage was not installed level by Mantec/LR so I have to create some spacers in order to make the rack level. This wouldn't be an issue with a rack that is just mounted to the roll cage (not using a combo of cage/gutter mounts).
For those of you who are interested there are now some wider roll bar clamps on ebay that are a fraction of the cost of my custom ones.
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