RideCO, I used a 4 inch grinder with a cutting wheel to cut the teeth out of 1/2 by 1/4 6011 alum stock. Took an hour or so. Really pretty simple to fab up once i puzzled out the design. Second one only took a few hours to make. 175 amp Mig welder does passable welds, but does take some experience. Weight 20 OZ for the pair. Had them in deep pow the other day and it was so nice The pow coating makes a lot of dif. and I'd do it on all the alum elims. Goodings perf. in Ft. Collins did the pow coating for 38 bucks.
You told us the cost for the powder coating, but what is the cost of the
"bushy boards"