I started this in another thread but had a request to post here with a more complete description. I was looking for an inexpensive way to carry my kayaks and didn't want to deal with rust. So, I decided to try PVC and it has worked O.K. for over two years. I must admit I have had to replace a couple of T's during cold weather. It seems that the PVC gets too rigid and is more susceptible to crack at T joint. However, that is much less expensive than the cost of an aluminum rack.
Sorry, no official plans, just custom cuts and fit to my truck.
I used 2 inch schedule 40 PVC.
8 - "T's"
8 - 45 degree elbows
small can of cleaner
small can of PVC glue
and several sections of pipe.
I attached it to my truck by cutting sections of 2" x 4" and fitting one end to go inside the 2" PVC and the other to fit the bed rail holes. I left the end that fits into the bed rail slightly longer than the depth of the bed rail hole so the rack rests on the wood rather than the bed rail.
The front and rear bed rail width is slightly different on my truck so measure twice and cut once applies.
I will break the post into several parts so I can show all the pics.
Pictures continued in next post.
Sam, Deb - DW, 2 Scotties: Kate (the Queen) , Morgan - the rescue
2009 Chevy 2500HD D/A, 2010 Eagle 322FKS
days camped 2009 - 54
days camped 2010 - 155