It is likely that both you and your buddy had different expectations going in. It seems like you probably had a vision of a commercial grade project, with cnc laser cutting, smoothed edges, precision bends, etc...
I've had those visions when I start projects too, and then I quickly start making compromises, in wood or metal, the build of the first one never goes as planned.
The commercially available projects we have all become spoiled by involve hundreds or even thousands of hours planning, trying, planning, test fitting, and trying, and planning and trying... You get the picture. That is part of why we choke on the thousands of dollars some fab companies want, when we only see the finish... A few hundred dollars worth of steel and some welding.
I note you said you specified to the 1/16" level. That would have been a red flag for me. Precision costs big money.
In the field, farm, construction, mines, most places I've worked, we've always had a saying- "draw with computer, measure with tape, mark with chalk, cut with torch, weld with stick... And sometimes... Install with hammer"
I don't know you, but if you don't want to spend a lot of time cleaning that up with a flap disc and file, you might be better off selling it and going with a commercial solution.
The intention of this post wasn't to argue over my disagreement, that is long since done. But since you commented, I have zero doubts this was a rush job. If you want the full picture:
I live in a different state from him but I've seen his fit-and-finish first hand. Don't get me wrong, I have background in custom manufacturing, doing professional grade robotics with custom CNC'ed and precision machined parts. I wasn't expecting this at all, I expected the level of work I've seen him produce for others. I don't need accuracy to a 1/16" I just gave him measurements that accurate so he can plan accordingly. Presumably, if there is a maximum width, you would undersize the mounts and potentially shim to fit. Not overshoot the goal. It was suppose to mount on the inner face of my 1/8" bedrails. It barely fit over the outter face with some shoving, it was no where close to fitting on the inner edge.
We lived in separate states, but I knew I was going to be traveling by him on a trip so we agreed at the very beginning there is a fixed deadline of when I will be by.
A timeline:
We agreed 6 months out that he would build me some rock sliders.
We agreed 3 months out he would build me the rack (I confirmed with him this would be enough time, in fact I confirmed numerous times that he would have enough lead time and there wouldn't be an issue).
All was paid full in advance, with rough CAD drawings to show the general idea of the rack (no specific sizing on my part, but to give him an idea of what I wanted from the design).
He begun working on my bedrack ~2 weeks before the deadline. I never recieved photos of the mounting brackets at any point during this time. All I ever saw was the tubing shown forming the "skeleton" or whatever you want to call it of the tray.
He came to me with 3 days from the deadline telling me he would be unable to produce the rock sliders (no work was done whatsoever, the material was purchased but nothing was ever built. Nothing was even planned to be built).
He came to me 2 days from the deadline telling me our previous plan to powdercoat the rack was not going to work because of what he planned to build the tray out of.
He goes AWOL for 2 days, and meets up with my buddy and I 2 days after when he was suppose to meet us after numerous phone calls, with a rack that barely fits (and not in the way it was designed to), no straight cuts on the mounting plates, sketchy maxtrax mounts (a single ~2" wide strip of 1/8" steel that was clearly cut by hand and not square welded onto the mounting bracket per end, one of which broke off the next day within 30 minutes of driving and the other flexed any time I touched it). I dont need precision shaped edges, I just would appreciate if someone hit it with a damn file instead of leaving a jagged obviously hand-cut edge on it. There is a big difference between low precision and low quality.
It takes me nearly 2 months of him ignoring me and avoiding all forms of contact to get him to agree to pay me back at least for the rock sliders I never got and the powdercoating I never got.
Keep in mind, this is not a guy doing some fab work for fun as a hobby. He wants his own fabrication business and is currently doing his work out of his shop on his property.
AAAAANYWAYS rant over.
You could probably fix the oversized brackets for $30 and some sweat.
http://www.harborfreight.com/4-12-in-43-amp-angle-grinder-60625.html
and a couple packs of cutting wheels and a grinding wheel.
Not being facetious. You can trim up those mounting brackets to your satisfaction. The rest you'll have to pay for again.
I guess I'm probably not being clear with what it needs. I'm not afraid to clean it up and round off edges if need be, but the brackets aren't oversized. The whole rack is about 1/4" wider (side of the bed to side of the bed) than it should be so it doesn't align with my bedrails properly. Each bracket needs to be cut off, the support bars(? or whatever you want to call them) need to be narrowed, and the brackets or new brackets need to be welded back on.