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The 2x6 steel tube are probably big enough. I made one with one 2x6 wood flat, one vertical, and another on top flat to make a channel. It was a little flexible, but stood up to 165 bales per load. I think you work too hard with the oak cross pieces, then long planks. Just cut your planks to 8' long and screw them to the steel tubes with truck deck screws (McMaster-Carr 90390A550). You will need to drill and countersink holes in the planks and to drill tap holes in the steel. These screws cut their own threads. Then along the edges (front and rear too) bolt down a 2x4 flat to keep the bottom bales from squirting out from under a tall load. I used 1/4-20 carriage bolts every 3 inches or so. When the wood has cured, tighten up all the bolts one more time and beat up the threads sticking past the nuts on those carriage bolts so they don't fall off. The 2x4 also helps share the load between planks that ought to be at least 6, preferally 8 or 10 inches wide. A couple coats of house paint will make it last a couple decades, at least. A length of 1" or larger angle under each side is another way to make it stiff and then leaves a lip for hooking on ratchet straps to hold the load for long distance deliveries, but the 2x4 are still needed. My main rack has tower legs, that's 60 degree angle, under the edges but I had to add the 2x4 to hold the bales on. Gerald J.
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