Wanted a cleaner look when the hard top was removed on our Bronco. This was a very manual machining project and really, to large a project for my tiny machine shop, but like most machinists do, you find a way to make what you want with what you have. We are happy with how these turned out.
I started with ½" aluminum plate 5" wide and shaped it with a Jet band saw, then finished the profiles with a 72" belt grinder and files. I used a Jet JMD 18 Mill Drill to drill all the holes and to cut the slots in the top. Then I had them powder coated for a nice matte black look. Definitely a large project for my tiny machine shop and small machines, but if you get creative it is amazing what you can get done with the tools you have on hand.
If you don't have a milling machine, I think a series of offset drilled "dimples" in the top would also give a nice look. Maybe 3/8" drill but only go 3/16" deep. Or even better, get a ball nose end mill and drill the dimples with that.
Could not be happier with how these came out. I have seen some plastic tub covers or bed rails available for the Bronco, but was not happy with how those looked. I really like these.
You can see all of our Bronco mods over on our @BadToTheStone Channel
Thanks for watching,
Bud