Hybrid Roof Rack (sorry 4x4mike)

[Seanz0rz]

Get yourself one of these in aluminum:http://m.northerntool.com/shop/tools...277BoCvKLw_wcB

It will allow you to mark the angles on the tube. I cut all mine with a 4.5 angle grinder and cut off wheel.

[Kryptoroxx]

Get yourself one of these in aluminum:http://m.northerntool.com/shop/tools...277BoCvKLw_wcB

It will allow you to mark the angles on the tube. I cut all mine with a 4.5 angle grinder and cut off wheel.

I have been using one of those for years but with wood lol. The thought didn't even cross my mind that it would work for what I'm after (although it probably should have)

THANKS!

I am still considering building the guide to help steady my hand but I might give the first cut a try and see how it goes free hand.

Here's some pics from last night's work. I have built on a hook for my leads with the welder cart. My goofy butt miscalculated the space I needed for the castors to clear the frame and ended up adding camber to my wheels. The cart is VERY stable and while it takes up a bit more room I am satisfied with the result given the fact I planned out nothing with building it.

[Seanz0rz]

My advise for the grinder is let it do the work and never force it. That's how people get hurt!

[Kryptoroxx]

Pressure also flexes the blade and gives you a wider and concave cut.

And if you're unlucky like one of my friends the blade busts at 13k and imbeds itself in your face.

Yep the blade does the work. Easier that way.

[Robinhood4x4]

Well a sanity check would be awesome since my wife is great with latin and classical knowledge a ruler and protractor are not her greatest assets.

So this is how I'm measuring the cuts. First of all the middle of measurement x will be the middle of the triangle. When I look for the angle of A I do this by taking 180 deg minus the inside measurement of the angle. In my first angle I'm looking at 150 deg so the angle I would use is 30 deg right?

When you make your cuts, make sure you measure the length to the longest edge of the steel, not to the middle of the angle. Otherwise you'll end up short.

[Kryptoroxx]

When you make your cuts, make sure you measure the length to the longest edge of the steel, not to the middle of the angle. Otherwise you'll end up short.

Not sure I am following but if you are referring to making the cut on the far side if the line to account for the kerf of the cut off wheel then yes absolutely I agree.

Not sure what the kerf of the cutoff wheel is yet but I imagine it's somewhere around 1/16th.

[Kryptoroxx]

When you make your cuts, make sure you measure the length to the longest edge of the steel, not to the middle of the angle. Otherwise you'll end up short.

Wait....lol I think it just clicked.

In my case since I am making a octogon I will always measure to the outside of the shape in order to get the correct legth of the sides.

[Robinhood4x4]

Wait....lol I think it just clicked.

In my case since I am making a octogon I will always measure to the outside of the shape in order to get the correct legth of the sides.

Yup, that's it. (Not that I've ever made this mistake before...)

[Seanz0rz]

Even though metal is a bit more forgiving than say wood in this respect, it's easier to grind a little off than it is to fill big gaps. On something like this, I'd cut .0625 larger then grind the angle perfect.

[Kryptoroxx]

Even though metal is a bit more forgiving than say wood in this respect, it's easier to grind a little off than it is to fill big gaps. On something like this, I'd cut .0625 larger then grind the angle perfect.

I agree especially on stuff that isn't very thick. Need to pick up a digital protractor so I can easily check the final angle after I make my cuts. I just found one on Amazon for 20 bucks or so.