Tomorrow I plan to order the aluminum rails, as I hear they have a lead time of up to 2 months (I hope not!).
Which AL rails are you refering to? If its stuff from 80/20 then mine took a week and half to get to my door.
I was planning on making a 4x4 table but now wondering if I should make a 4x6 table. This would allow me to be able to cut roof rack parts up to 6 ft long. From what I can tell the cost to make it 2 ft longer is only about $50 additional on the side rails.
Any thoughts on a 4x6 vs 4x4 table?
If you have the room for a bigger table then I would step up to a table that can handle 4x8 sheets of metal or 5x10 depending on what your local metal supplier has. Being a offroad shop I would think a bigger table would benfit you more.
Are all your parts common things that you cut out the same everytime or have a base model then modify for the application?