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Originally Posted by 79T/A
I like V's idea the best so far. I have a tendency to go overkill on stuff like roll cages and seat belts, so I'd take it one step further and sandwich the sheetmetal between two pieces of 3/16 or 1/4 steel plate. I'm assuming that the top plate could be hidden by the rear deck's cover.
And I don't trust Home Depot for steel or Grade 8 hardware. I've heard that the stuff they sell is cheaply forged and therefore not as strong. I don't know where in the north you are, but I go to Tractor Supply Co for the Grade 8 and RS Phillips in Vernon for the steel. They've got a fantastic short rack full of cut offs and what not that's sold for about fifty cents a pound. Bring cash and walk out with a bunch of good steel.
And the reason I asked about the age: Depending on her weight and height, the four year old could probably still be in a car seat with a harness, which would temporarily solve the problem. Most of the newer seats are rated up to 65 pounds with the harness.
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I'm in Bergen County - Vernon is about 1 hour away, but there are a few steel suppliers that are more local. I'll give them a ring and see what I can find from them -thanks for the tip on the HD stuff. I like your idea about putting a plate on top as well, so after I find out what's available in the area I'll make some changes.
I also thought about keeping the other car seats, but they were 6 years old and the belts were starting to get a little worn, so we just picked up Graco flat booster seats for her too. I'm sure this will work eventually - just gotta find time to get them done.
Thanks for all the ideas guys, you've all been a big help!