Annealing will certainly help to prevent delamination. Hurts for mass production though, since I'm guessing you'll be getting requests once you get it spot on. I like the new design.
A 2012 Nissan Xterra. It was a good ride, but I got a job in a neighboring city and the 14 mpg was too much. I needed a cross between highway comfort and off-road ability. I went in for a Maverick and came away with the BS BL.
I would think Carbon fiber-infused PETG would be a better option(as it has a higher glass transition temp.), but still not as good against the effects of UV radiation as ASA, from what I understand.
I'm curious to know how you would print this to limit delamination? I'm guessing the rear of the part would be on the build plate? If you have a belt printer, the bottom could be on the belt and the layers would be at a 45, which could make the print more robust.
As an aside, I would elect for...
You may need to do some work the make sure that size doesn't rub.
I second the HRG Engineering lift. But the one from fordrangerlifts.com looks like a great kit too.
I agree anything more than 2 sheets of 3/4 I would probably just rent one of those those hourly vans from home depot. It's not worth the potential issues.
That is an interesting insight that I did not consider! Although; I am sure that is well below the actual ability of the rails, as a rooftop tent must weigh a fair bit and the weight of an average single American is already in the upper range of that value.