well, here's my roof rack
 

I used emt conduit, some scrap aliminum plate, and used some 1/4 20 thread inserts to screw it together with. The thread inserts flare on the inside when installed making them solid and they won't pull out. Took measurements, made bends and welded the ends together, I installed a 1/2 inch close nipple into the ends and then welded, that will help keep me from burning through and help with rigidity. May not have needed that, for one i put the ends at the side supports so the side support will support the joint.
I have not put bottom in it yet , I will post that when I get it done, so here's some pics for ya.

http://i812.photobucket.com/albums/z...h_PICT0001.jpg

http://i812.photobucket.com/albums/z...h_PICT0004.jpg

http://i812.photobucket.com/albums/z...h_PICT0006.jpg

http://i812.photobucket.com/albums/z...h_PICT0008.jpg
http://i812.photobucket.com/albums/z...h_PICT0005.jpg

More pics
The insert
http://i812.photobucket.com/albums/z...h_PICT0051.jpg

Looks like once installed
http://i812.photobucket.com/albums/z...h_PICT0050.jpg

http://i812.photobucket.com/albums/z...h_PICT0053.jpg

http://i812.photobucket.com/albums/z...h_PICT0057.jpg

Couple more

Tool used to install inserts
http://i812.photobucket.com/albums/z...h_PICT0054.jpg

http://i812.photobucket.com/albums/z...h_PICT0060.jpg

That looks very nice well done.

looks great

Very nice!

Did you do the bends?

Yes, I did the bends. I have run a lot of conduit over the years.:thumbsup:
Thanks for the compliments.