What'd you spend on materials?
i forget now, that one was way over built, another member here bought it from us. i think we spend around $250 or so on materials, but we had to buy 20' sticks i think it took like two sticks. it was way too heavy, i think we used like 1/4" wall lol and with the expanded metal flooring and all the cross bars... well lets just say it was our learning curve... it took three guys to put it on or take it off. we have sense built two more, each time cutting wall thickness and cross bars our next one is going to be 1/8 wall tubing. and i think we will try to go back to the expanded metal floor, i like it alot better. but right now we need to find a new PCer, as the last one sucked and my rack wasnt coated good enough and is now starting to rust. in less than 6months

:infidel:, needless to say we are quite pissed at the guy and he is being a jerk about his work -making every excuse in the book(and they are all stupid -like "i didnt know it was going to be something that was going to be outside in the weather ect...:wtf
anyhow each rack we have made has gone down in cost of materials, but time and energy is still high, because we do not have a set patter yet so we have no "jig", its all by hand and carefully laid out on a table and measure, cut, measure, tack, measure, weld, measure, then repeat for each piece... its a long process and untill we get a set design down that we like and others like most of our work will take some time. its not something we want to be knocking out on a sunday afternoon, and put our name on. and sense this is not our main source of income(we have other jobs, this has to be done on spare time, basically as ordered basis) i was just approached by the sheriffs office to build some racks for some of their rigs and for the SAR group. so pretty much all of our stuff is custom one off at this point.
those are all pics of our current rack, the two lights on the edge up front are 6" and the three in the middle are 7". the light bar is removable and also set up for multiple lighting configurations. the rear lights are roughly a 3.5"x6" lights, and the tire is a 285 70 17. as you can see the rack provides very little obstruction to the sunroof(does not impede function at all), and without the light bar there is no obstruction. the rack is about 40lbs with out the light bar or lights and mounts to the factory rail system. this rack is still way over built and again the roof would fail before the rack would.