Great job on the rack. Anymore pics of how you mounted it? Close ups of the brackets? Thanks.
Hera ya go...really straightforward. The alum angle 6061 (I think it is 1.5" x 3/16"...might be 2") I had laying around. It is used in scaffolding. Unfortunately it already had some holes drilled in it and I realized it after I cut the brackets (oh well) ... Don't worry, the hole for the factory sport bar mount is drilled next to the existing holes - but hard to tell in this photo. Looks like hell, but gets the job done and is hidden. I used large grade 5 fender washers here to spread the load over the aluminum. I used M6 flange bolts screwed into the soft top mounts. I had to run a thread cleaner (not a tap) through the factory holes as the threads were partially galled. This mounting location raises rack up off the floor quite a bit and won't work with a soft top (not a concern at the time). I used flange nuts & bolts to make it as easy as possible to assemble (I hate washers).
The seat belts operate fine and do no rub on the rack while in use. (The side nets do get in the way, but nothing of concern).
I spoke to a mechanical automotive engineer familiar with the mounts in the roll bar. He said my mounting is more than sufficient for the rack and expected weight. He felt this was a better mount than using the clamp methods of some aftermarket vendors. He suggested if I was going to exceed 75#, to add long a bar on the other side of the factory tube to reduce the moment arm of the rack (prevent the rack from rotating.) He thought my floor bars were outstanding, but overkill unless I wanted to add more weight and suggested I simply run a flat bar to the rear hard top mount instead if I was really concerned about it.
I still haven't cleaned up the pipe insulation yet. Ugly, but functional. It is on my list of things to do.
You can see some of the holes and witness marks from the floor brackets as well as the brackets used to the hang the half shelf. The half shelf has been removed in these photos. I use wing nuts to hold it on.
You'll also notice a C channel that bridges the two halves of the rack. I was not satisfied with he amount of flex at the center point in the rack so added the c channel between the two rails and across the front. I am pretty sure some/all of this c channel was in the kit from HF. Just needed to be drilled/cut to fit (I can't recall).
I also included some pics of the hooks I used to add some tie down points along the hard top. I replace the bolts with some that are slightly longer and added some large diameter grade 5 fender washers to pravent the hooks from cracking the top.
There is a high current aux power port circuit (20A via #10) that is switchable - it can run from the main 100ah battery/alternator or run off my sealed 110ah AGM battery located under the rear seat (charged via CTEK).