Originally Posted by
Hopslam
Yakima rack bars are 1-1/8 od and electrical EMT thin wall 1" size have the same OD. I made some 92" for mine .10' section is less than $5 & a78" yak bar is about $40+
they are plenty strong as long as you don't hang a bike out over 20" passed the tower!
Cheers
EMT is quite malleable -to increase the PSI needed to deform and bend them fill them with "great stuff" self-expanding foam. It doesn't add much weight but makes them about 2x as resistant to bending as the foam needs to deform inside the conduit in order to allow the pipe to bend and the tightly-packed stuff does a good job of resisting deformation.