Hey, you guys have been great! I still don't have my solution, but I
think we're getting there.

In review, my own particulars a a '94 Ford Aerostar where dents and
scratches are not an issue (Hell! It's an Aerostar! Was there ever a
cheaper van made?!), no commercial roof rack, just the thing that all
Aerostars come with, and a short (5'7"), stocky guy who can carry and
horizontal lift the 90 pound kayak to a height of about 4.5' (I've not
tried clean-and-jerk... maybe after a few beer). After just two trips,
I've just about perfected (and really like) the "front end on the front
door" maneuver. BUT, Cyli's got me worried and thinking alternatives.

I think Tink has a point re the conduit; after all, it was made to be
bent. I went to the hardware store this morning and tried a bit of
pressure on the pipe and I was able to put a bit of a bend on it
without much effort. I then thought of going one dimension larger for
each of the pipes (greater diameter = more difficult to bend, right?).
I would have purchased right away had it not been for the price. I need
to find me an electrical shop that has "ends" (about 4-6 feet worth of
ends) kicking about.

As an alternative (and it was something one of you said, I'm sure), I
could go very crude and very elemental (if the material strength is up
to the task). Tell me what you think...

Two approx 7' pieces of 1X4. Place one lengthwise, on the left-hand
side of the van, under both roof rack crossbeams. Then, place the other
1X4 under, and at 90 degrees to the first 1X4, with about 3' jutting
out over the right-hand side of the van for me to place the kayak on
(this piece would be secured, with rope, to the crossbeam to ensure it
doesn't slip as the weight of the boat is placed on it).

Why 1X4? Because nothing thicker than 1" will fit under the crossbeams
and still allow another timber to be placed under it.

Question to all you bright guys: will the 1X4 be strong enough to hold
the kayak?

Cheers,
Wilf