I picked up my rack from Josh this morning at my local Greyhound. It was $70 to have it shipped from the panhandle to NE Tennessee. I'll do my initial review here and then fill it in with the final details after I get it finished the way I want (powdercoat). A few things to keep in mind: I'm extremely picky about the upgrades I do, and I tend to hold my upgrades to a high standard, especially things that will be mounted in constant view and subjected to weather and heavy use. *I'm writing a very detailed review for the sake of others who may want to order a rack from Josh, which I wouldn't hesitate to recommend.
Weight - My first surprise came when I picked up the rack - it's extremely light. If it's strong structurally, this is an incredible bonus. It can't weigh an ounce over 30 lbs. Very pleased with that, but the strength of the rack will be tested soon enough. For now, I don't expect it to affect my MPG by much.
Welds - The welds are good. I checked the majority of them, they seem to have penetrated well. They could use some grinding to pretty them up, but I'm actually pleased to do that, as it will give me an opportunity to "work" on a project I otherwise would have not been able to do. I've seen prettier welds, but the price to quality ratio here is very good.
Build - Extremely pleased. The lines are straight, the measurements are accurate. This rack was built with one square line down the middle and a few bars going across. If I did it again, I would have two bars running front to back (offset) instead of one in the very middle. One in the middle creates large rectangular dead spaces on either side. 2vs1 would add more support for the aluminum flooring I plan to put in. I'm also pleased with the light mounts. They're long and un-drilled, which is going to allow me to cut them down if I want based on the lights I mount, and drill my own hole customized for the hardware I'm using.
Complaints - My original plan was to open it, give it a quick cleaning, and hit it with primer and paint. This would prevent rust until I can get it into the booth for sandblasting and powdercoat. Well, the packing tape used to secure the cardboard to the rack is hanging on like it's being paid. An hour after starting, I had a floor full of cardboard and a rack covered in tape residue. Sanding and acetone will come tomorrow, then hopefully primer. A minor setback, but an inconvenient one nonetheless. This is my ONLY complaint so far, and it's me being anal. Sort of.
Final (initial) thoughts - Although strength and longevity remain to be tested, the overall quality of this rack is superb for what I paid for it. If you're thinking about buying one, don't hesitate. The reality of a custom built rack for under $300 to my door is brilliant. If I had two 4runners, they'd both be getting racks from Josh.
If you decide to order a rack, my suggestions are few. Order un-drilled light mounts, I'm glad I went this route. Second, have two parallel offset bars running front to back instead of one down the middle for more flooring support. Third, ask to have the whole damn rack put in a box. It'll save you hours of prep time. I'm well aware that by the time I powdercoat I'll be approaching the cost of a Baja Rack. But to have input on the build, be able to cut, grind, and paint myself, this is a steal.
Josh, figure out how to build a good ladder for the rear door and give me a call.
