Congrats on the rack order and I do not think you will be disappointed. I will caveat that same statement as saying the reason FR and so many other racks are popular globally is because of the aluminum design. For southern California or straight desert environment, you will probably be okay for the long term. The minute you scratch the powercoat, youre exposed to cancer anywhere else in the world and the days are numbered. The welds are going to be the first point of corrosion under the PC, it's just a hard place to completely rid of contamination unless its acid dipped prior to PC and then immediately sealed and primed.
That was my biggest selling point, aluminum contruction for weight and corrosion prevention. My TR front steel bumper is starting to rust and its been less than a year. A couple of scratches and there is no controlling it and of course the welds as I mentioned above at the bull-bar.
My roof rack corners on the FR are corroded and I think that is bad pot aluminum and FR needs to quality check that because I know I am not the only one dealing with it. Not to mention, 10 years into the design and still no factory wind fairing option!
However, the rest of the rack is scratched up pretty good from trail rash and roof rack gymnastics with kit, absolutely nothing to worry about outside of asthetics. That is not the same luxury with a steel rack. I wet installed the Grade 8 hardware to the roof, and replacing all of the M8 and M6 bolts with stainless in not structural areas.
Aluminum, steel, and cadium are three things that do not work well with each other. Wet install all of your roof hardware with corrosion preventative compound (CPC) and you should be okay.
You are 100% on the mark about looks and design. They have all the right things covered I think outside of not going with stainless at a minimum for construction. I believe I would pay a few hundred more for the materials to add to longevity but stainless is also brittle so I can see why they do not like that for roof racks either as they crack at joints relatively easy.
These were just a few reasons I stayed with the FR rack.
I literally ordered the Baja rack about an hour ago haha.
I have read lots of great reviews actually. I really like the look of it, and the size. I am going to roll the dice on it.
I do not like the front runner, or the pro speed, and I dont particually care for the Gobi racks either. For me, the baja rack looks to be the only one that ticks all my checkboxes.
We shall see how it goes!