Aluminum Roof Rack

[AlexJet]

Building new aluminum roof rack for my 4th Gen 4Runner come to the problem.
My rack design has small radius aluminum tube bends (1.5" OD tube with 5" outside radius). I looked everywhere and found only one place who sells such elbows. They are 32.50 each + shipping.
Now I come up with another issue. At this moment I need 3/4" or 1" OD tube with 90 degrees bends and inner radius not bigger then 3.5". I can't find any elbows or U-tube. I want to make something like Baja-style light bar from 3/4" or 1" tube. Do you know any places i can get them from?
I tried Baja-Designs if they can sell just a light bar without lights, but no answer so far and based on their website I don't think they will do it at reasonable price. Any ideas of where else I can buy parts or ready fo use light-bar like this one:

 

[ExpoMike]

I think part of the problem of not finding these is that most are bending their own (or whoever is building the part). Most light bar and roof racks are bent in a U for each half and then welded (or bolted) together at a one joint so in reality you are only using two pieces of tubing jointed together to make one item.

You don' typically see them create these items made up from bent and straight piece of tubing, where you end up with a lot of joints, welding and cleanup of welds. Not practical on a large scale operation.

Sounds like you need to find (or buy) someone local that can bend the size tubing you need but you'll need to have all of your demensions figured out first. Myself bought a tubing bender with a 1.5", 7" radius die for building a roll cage and lately a hoop bar for my bumper. I have also bought a small tubing bender set which will do round and square tubes up to 1" for my upcoming roof rack project.

Not sure if this answered your question or helped to figure out why you can find what you are looking for. Best of luck. :sombrero:

edited BTW, most pre-done light bars and racks are going to be ??? Most light bars like the one above will most likely be in the $250 and up range, based on what I have seen available.

 

[Sloan]

www.woodwardfab.com In the bender section check out the one that says "As seen on Trucks TV."

 

[ExpoMike]

www.woodwardfab.com In the bender section check out the one that says "As seen on Trucks TV."

Yep, that's the one I bought. Low Buck Tool builds the bigger one I have. http://www.lowbucktools.com/hydbender.html

 

[ntsqd]

Something like this HF bender could be made to bend tubing in the smaller size ranges. I would have round tube dies made or make them. Those supplied really aren't intended for use on round tube.

 

[Spikepretorius]

That looks lightweight. What about soldering up some copper plumbing bends and pipe?