steel suggestions for a safari rack

[spabula]

I am looking to fab a safari rack and would like some suggestions on Metal to use. I have some 1" square tube, 1/8" wall. But I'm concerned it will weight A LOT. My other thought is EMT or rigid EMT. That seems a little light but if I reinforce it enough I think it'll be ok. The rack doesn't need to really support a whole lot of weight. Plus its like $0.25 a foot (or free from work ).

Suggestions?
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[KPSquared]

A lot of the racks on the market are made out of 1" steel tube. Usually about 16 guage, so .064" wall. I plan to make mine out of aluminum just because of the weight savings. I need it to be strong enough to hold a tent if I ever mount one up there.

There was about 50lbs difference b/w an aluminum rack and a steel one. A big steel rack can weigh like 80 lbs, and an aluminum one could get down to under 30...

I don't like the look of square tubing at all, so I would try and find round. If you can bend and weld, your rack is going to look way better. If not, just make do with what you have and get creative.

Check out defenderrack.com for good ideas and sweet racks!

 

[spabula]

EMT is .057 wall, so right between 17 and 16 gauge.. i might give it a try..

The rigid conduit that is aluminum is .107 wall........ thats roughly 12 gauge..

I dont have a spool gun for my welder so ill probably stick with the thin wall steel for now and see how it goes!!

I'll post up some pics when i get it together.