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I have a fabricator/vendor that specializes in stainless steel.
He has some 3" and 4" s/s tubing available at a cheap price.
I planned on having the ends fully welded, and just having a straight bar.
My questions are as follows.
1) Is 4" too big? or will it look tough?
2) Do I need to use all 4 mounts. I have an extended cab and want to go wheel to wheel. I have seen nerf bars on ebay with only 2 mounts. I hate to see it bow in the middle. Perhaps some field testing is in order. I dont know the thickness of the stainless. hopefully 14 ga.
3) At the step points I would think it may be slippery at times. Any Ideas besides notching and welding in flat steps? (labor!!) I have diamond plate available to wrap a few 12" wide sections of necessary. I know there is also the cheezy non slip stickers that will look cruddy fast. I also have a laser and waterjet available to do some kind of pattern, but I am concerned with debris getting inside the tubes.
If you weld the ends all the way around,drill a 1/8" hole in the bottem somewhere to keep them from splitting.I have seen this happen,something to do with condensation and freezing and thawing.
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