Will do. Haven't completed the painting yet, deliberating using your method rather than the PVC. Using the right angle iron pieces puts all of the stress on four bolts (the ones attaching the two pieces of iron together on the side of each rail), but on a 400 pound roof load that would only be 125 pounds per bolt. I think Grade 8 would handle that type of shearing stress. Maybe put JB Weld in addition to the bolts?would you post some pics of your setup? also, if you use electrical PVC which is gray in color, it is UV resistant unlike white PVC which is for plumbing. or, all you have to do is paint it to protect it from UV
Using the PVC spacers puts the stress on the spacers (since they would rest on washers directly on the factory roof rail mounts) in a straight downward direction, which may (maybe not) be more structurally sound. Of course in my case it matters little, since anything I put on the roof would be a light load.
(As you can probably tell I tend to over build - a habit brought over from driving Wranglers).
Probably won't get it together for a couple of days; although I'm semi-retired I've been recruited to write a database for a non-profit org in my area and that's taking up what would normally be free time for me.
I did a test fitting (of the unpainted pieces) and things seemed to go O.K., except for adding the spacers.
I'll post pics as soon as I get the remaining bits 'n pieces assembled.