I use 16 of those clamps, it's a bit over kill...hehe. I used insolators to reduce vibration and noise, I don't even know it's up there. Even when I wheel I don't get any rattles. Only noise I get is from the damn lights and rack from the wind.
Al- I hear you about the lights rattling. My jack rattling gets a little anoying too. Anyway, I like your securing method. Looks good.
Paul- I had a local fabrication shop do the flooring for me. I think it ended up costing me $250 or $300. My only beef is that I didn't measure the rear securing holes good enough. Securing my 1650's is a little pain. The front worked out perfect for my 1600's. All in all, it beats the hell out of wire mesh!
I have some flooring in my DI rack that I really like, it was CHEAP ($7.00) I can walk on it, I can secure loads to it at any point, it is light (about 7-10 lbs.) and easy to install:
This web site is where I have the photos of the truck for sale, but it shows some pretty good shots of the roof rack: http://landrover.mrbaileyshistory.net
It is galvanized fencing that is used for building small corrals etc., but works great with a pair of bolt cutters and pipe clamps. I used flat black spray paint and it is over a year old without chipping.
14 Gauge alum diamond plate, It runs me about $75.00 for a 4x8 foot sheet, Mabey even 4x10, I forget, But it is easy to work with and is great to satnd on, So, that is my vote, You can also cut it with regulat metal shears from Lowes or your local hardware store! Good luck with your project!
I went to Sam's and got the jig-saw looking floor rubber mats and used that on my Hannibal Safari rack this weekend. It seemed to do well for the first run. It's light and I just added the number of pieces that I needed for the application. I had rust marks and dents on the rubber from the jerry cans and it protected the rack real well. I think it's worth it for 10 or so trips...I'll recycle it over time as floor mats in the garage or something if it gets too bad...
This is some tuff stuff as I tried to tear a piece off to use it as a cushioning piece later on. The stuff I got was grey and cost about $15 US$....
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