: I'm about to start on making a new set of J-type racks for my
: pickup, in steel. The old version has worked pretty well, but, I
: intend to A) make the posts 4 or 5 inches lower; B) incorporate
: better strapping points; C) incorporate a hinged/pinned design
: that will allow the cradles to easily swing down so I can pull
: into the garage with little fuss.

: I have to figure the padding into the dimensions, and would like
: suggestion on materials that can be re-purposed for this task.
: In the past, I've used pipe insulation for towers, and dock edge
: bumper for the lower parts. I want to go with something more
: unified, and a little nicer looking (and more durable than the
: pipe insulation, and a bit softer than the dock bumper).

: One possibility is thick wall rubber hose of about 1 1/2 inch
: diameter. It could follow the entire J. It could be attached
: with screws, through the wall in contact with the rack, via
: access holes cut in the other wall. The wall thickness would
: prevent the screw heads from ever protruding through the access
: holes where they could do damage. Hose used like this would seem
: to have some padding benefit due to the crush of the sides, and
: the 2 layers of rubber.

: Here's what the current racks look like (a modified Werner ladder
: rack). The height of these was set so that ladders and lumber
: could be hauled. Since the new racks will be for a single kayak
: only, I can go lower, and still be able to open the door.

: Due to limitations of equipment and skill, I will be working with
: square tubing and angular welds, rather than round tubing and
: graceful curves.

: Ideas?

You're already way past my welding ability :) I made a T bar years back for my then pickup that worked fine, but it wasn't as polished a design as this one. Gave it to my brother-in-law, no idea what happened to it after that.

I've fought the padding issue on our club's trailer and never did find a really good solution, looking forward to hearing what others have to say.

Bill H.