I spent about an hour at fab shop this morning tweakin' the design of the mounting tabs. I wanted them as flat as possible against the body for the most surface area to distribute the load. Tabs are 1 1/2"x2" and are flat on body so the load is over a large area.
Still need to get powder coated but out of time for MOAB trip. I can still access roof rack from rear bumper. I installed rack, spare, and stood on rack... minor bounce with my 200# moving up there... I plan on replacing stock carrier stubs with bolts, not comfortable with amount of thread contact on studs. It's over built, I'm sure I could trim quite a few pounds from rack with a redesign.
Fingers crossed that is stays put... time for a beer...
