Hi Erik,
I received my rack several weeks ago, and I've been very happy with it. UPS gave the box hell, but everything was fine except for some scratches and some bent ends on the square floor tubes. I was able to bend those out a little with a screwdriver, and everything went together fine. Little plastic plugs of some kind might do a lot to protect them during shipping.
To be honest, I was amazed at how solid the basket is. There's a lot more triangulation in the round post setup than is obvious to the eye. I can stand on the top rail of the basket and shake the whole jeep back and forth without any movement of the top rail relative to the floor. (or the rack relative to the jeep; those 6 gutter mounts are darned solid.)
I received the end caps for the side rails that you sent me; thanks. That does help a lot on highway noise. You had mentioned some kind of front spoiler/airfoil was in the works to improve mileage. Any news on that? I'd love to get one.
Thanks!
fiz