A few more hours of progress this weekend...
I hit the local metal supply and had them cut me a piece of expanded metal for the floor of my roof rack. I trimmed the corners, sprayed it with bedliner and bolted it down. Much better for cargo now.
While I was waiting for the expanded metal to be cut I dug through their scrap pile and pieced together the ingredients for a spare-mounted Hi-Lift jack holder. The parts with the bolts are from Hi-Lift's mounting kit. They'll get used on my piece.
I made up a template and started trimming out the base.
Once it was roughed out I fired up the belt sander and cleaned it up.
Then I finished cutting the notch, drilled the holes and then crudely countersunk them for the lug bot heads.
A quick test fit and then I cleaned it up.
At the next step I realized that the bits I bought for the gussets are too short so I'll pick up some longer bar stock this week. Quick mock-up so you can get the idea of what's coming.