On 18-Mar-2005, "BCITORGB" wrote:

See what you think about this: I cut deep into the 2x6 crosspiece
(rectangular cut) and then create a sling using a fairly wide webbing
strap (perhaps 1.5" wide to correspond to the 1.5" cross-section of the
2x6).

The sling idea is a good one, but I'd consider a combination of cutting
a bit into the top of the 2x6 and also making little towers of wood to
hold the ends of the webbing.

Also, the ideal place to support the kayak is at the bulkheads - just
behind and at the front of the cockpit. The bulkheads provide plenty
of strength and stiffness to keep the hull from deforming.

The issue here, I guess, is
ensuring that the straps can be securely mounted to the crosspiece
(grommets etc, eh?).

If you make a couple of "towers" to hold the straps, then this is easy.
Bolt the towers to the crosspiece (two bolts will do it - sloping the
towers to the outside will allow for more length to distribute load).
The towers could be 2x2 or 2x4 and only need to be tall enough to clear
the hull from anything underneath. Round the tops of the towers and
run the webbing over to the outside. Double (or triple) the webbing
by folding it over and use a hot nail to burn a couple of holes in
it. When you cut the webbing, use a lighter or match to burn the
cut end and melt the webbing so it won't fray.

Screw thru the holes with stainless steel wood screws and use
stainless versions of these things (cup washers):
http://www.leevalley.com/hardware/page.aspx?c=1&p=40096&cat=3,41306,41316&ap=1
to hold the webbing.

Don't forget to allow for a place to attach the webbing that will
hold the kayak down on the rack. This can be big stainless eye bolts,
for example.

Mike