Mike,

Here are a few different examples (some good, some bad):

http://www.zoneworx.net/productTMR01.html




Real Wheels



Gobi



SMA Roof Rack



ORU Defender




Surco Safari

 

NOW THIS ONE IS THE **** and my personal favorite.....Kind of reminds me of something else....

http://www.boulderaccessory.com/shop...aspx?itemid=38

 

Those are just some examples of what's out there.....Food for thought so to speak.

I took some rough measurements today and it looks like 50X60 is a magic number...even out to 72.

 

Here is the rack I put together with "Speed Rail" made byhttp://www.hollaender.com/.
You can configure it in hundreds of configurations. This set up cost me about $250.
http://i22.tinypic.com/293ikwo.jpg
http://i22.tinypic.com/20m3k3.jpg
http://i21.tinypic.com/28m1xdl.jpg

 

i really like something like this,only bring out the front and leave it open,but bring it out for lights,.....i wonder what size tubing that is.do you guys think that the bottom of that is suffiecient,or should it be expanded metal

 

Bottom could be either or, even a combo, expanded toward the back half????? For roof racks, I prefer a smaller tubing like 1", the big stuff starts to look like your advertising for a sausage company???

 

i guess i shoukld just build it like i did that spare tire rack.1" tubing w/ some 3/8 bar as design and 1 " bottom bars w/ som expanded,pretty much sounds like a winner to me

 

That would look good if you matched it to your spare tire rack.

 

I have a Gobi Roof Rack w/ Ladder and I love it. I could not of made it cross country on the Cargo Space of the H3. I also added 4 PIAA lights.

 

I hate to say it but, you have a nice rack[:@]
I want the stealth rack, but I went to a local fab shop (Shannon Cambell owns it) he quoted me 700 for a Gobi stealth lookalike but with the lights and mounts where ever I wanted inluding the powder coat. I may just go this rout rather than making it myself. Now to get permision from the wife[8D]