Join Date: Jan 2012
Location: Yadkin County, NC
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2000 SE Xterra
I am actually about 90% of the way done building a rack out of 3/4 conduit. I havnt posted it in my build thread yet because I have been working on it slowly for about a year when I have time. Also I have been using my small wire welder to weld instead of screwing it together. I actually tapered mine towards the front a little. I want to say is about 2 inches less wide in the front than in the back where the tire goes. All in all I would say the thing is pretty strong. I weigh right at 250lbs and have stood mine up on the back side and jumped up and down around my driveway like a pogo stick and it didnt budge.
for the spots where I had to couple the sections of emt together instead of putting them on the outside and using 3/4 couplers I bought some 1/2 couplers removed the screws and then ground the area down where the screws went smooth. with a little bit of force you can push the coupler inside the 3/4 and then slide the other side over it as flush as possible. Then weld and grind smooth.
Word of advice to anybody that might decide to weld emt. first off it is a pain to weld. low and slow or you will burn holes all in it. second it is galvanized, so be careful. only do it outdoors if possible and avoid the fumes like the plague. It probably wont kill you if you breath in too much of the fumes but it will sure as heck make you sick as a dog. Learned that my first time around. After that I would only weld outside and then for about 20-30 minutes max before I took at least a 30 minute break. havnt been sick from it since then.
Apply dirt liberally, rinse and repeat
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