Let me see if I can explain how I load my Kayak on my truck roof to help you figure an easier way to load your boards.
I use Yakama Round bar racks on the top of my 4x4 Expedition rig. And as you can imagine it's tall. So I made a 20" tube that goes inside the end of the round Yakima Bar. I store it in the rear door pocket when not loading the boat. My 17' 2 seat Jocassee Kayak use to be a bear to load, but with the small bar insert I can raise up the nose of the Kayak and set it on top of the extension. Which is padded with heat shrink. It sticks out far enough from the truck body I can set the entire boat on the extension.
Then I go to the other end raise it up and push the boat toward the center of the truck roof. Once I get to the center of the boat I set the bow into the front Kayak Saddle, raise up the stern and walk it over to the rear Kayak Saddle. I can load this long boat by myself this way!
Then just remember to remove the rod insert from it's spot inside the Yakima Round bar and start strapping the boat down. Sometimes I even remember at this point to pop the end cap back in to keep down the wind whistle!
I use long straps that I toss over the Kayak and secure to the boat to the saddles. My saddle are almost 9 feet above the ground.
I know you've already made the cuts but, just so you all know!
I made simular brackets to attach my Gutter mounted Yakamia Rack to the top of my Pop Up camper many years ago, so I faced and solved the problem the same way you did. Great Minds!!!!
I work a lot with Aluminum. Even have an all aluminum race car trailer I built from scratch.
For cutting the Aluminum Tubing there is an aluminum saw blade made for use with either table or Skill saws. They have real small teeth and must be fed slow.
I use mine all the time to cut aluminum "I" beams. Some of the aluminum I cut is 16 inches wide and 3/8" thick. Band Saws work well with AL too! If you've got one!!!!!!
A table saw set up to rip your tubing (my preferred ripping tool) will work fine but like the guys said, be prepared for dangerous flying kerf. Goggles, face mask and long sleeve shirts are recommended.
And be prepared to sweep up your Aluminum Sawdust before you track it into the house on your clothes, hair and shoes because of the baby! Baby's live on the floor!
Another tip for steel metal shavings and specs in the eye sweep a magnet near the eye, but don't touch the skin or eye. The magnet will remove metal shavings and such without making contact. I keep a magnet pen on the side of my tool box and lathe just for this. But of course magnets don't work with aluminum. I have a nice collection of clear safety glasses. I buy them by the case and use them anytime I'm in the shop. Almost went blind from cataracts so I don't take my eyesight safety lightly!
Nice build! Enjoyed the read!
