Roof rack - hard mounting to roof

[dyogim]

I plan on hard mounting some Thule feet and load bars to the top of my tundra usig 3/8" nuts/bolts with washers and metal plating to spead the clamping support. There's two tracks on the roof that looks to be used for a factory rack. There's a 3"-4" section between these tracks and door I plan to mount the feet but, have some issues with access. There's a secondary layer for support I'll need to drill and cut.

Has anyone hard mounted a roof rack (thule, yakima etc.) to their roof? Rather than use the fit kits that mount to the gutters. If so, how did you support it, large washers, metal plating or none at all? Pics?

 

[spencyg]

I think the key is to spread the load at each contact point. If it was me I'd probably fabricate 1/8" steel plates maybe 4"x6" at each contact point which contoured to the roof at that particular location. Access to the back side of the roof will be basically impossible unless you want to go through the extreme hassle of removing the headliner. From those plates I'd fabricate some sort of removable socket system which would allow the rack to be removed from the base plates. After all that is done, goop the back of each plate/roof mount with a sealant (I prefer polysulfide...silicone on paint is maybe not such a good idea) and pop-rivet the thing right to the roof. Probably 8-10 rivets per plate would be adequate. I'm going to be doing this same thing with my van roof basket soon...

Spence

 

[paulj]

20 years ago I mounted a set of Yakima rain gutter adapters to the roof of an S10 pickup. These are pads, each taking 2 bolts, that can be the base for standard rain gutter rack supports.

For the front pads I slid the headliner back and used nuts underneath. In the back corners, internal stiffening prevented access to the under side of the sheet metal. There I used large self taping sheet metal screws.

I sealed everything well (too well?) with silicone.

Since then Yakima has adopted bolts that can be used on sheetmetal without access from below. I believe they are called 'plusnuts'. That is, most likely, what rack shops use to mount tracks to roofs.

I wouldn't do that again on a new truck, but if I had to, I'd use the tracks and their bolts. Tracks give the most versatility.

 

[dyogim]

Thanks for the replies. I already have the headliner out so at least I can figure out how I'm going to do this. Metal plates are definite. I'll post up some pics once I start the drilling. Once the rack is installed, I'm going to install a custom basket, install the driving lights from the bumper to the roof and re-run my lighting switches to my overhead console (modifying the sunglass holder).

 

[dyogim]

Almost finished with mounting the thule feet and load bars. Then I can get started on the frame for the platform (approx.4'x4'). I used the factory tracks (which is the thickest part of the roof) and drilled two 3/8" holes for each foot. I'll post up some pics once I'm finished.

 

[paulj]

A nice feature about the Honda Element (and the CRV) is that Honda provided roof rack mounting points under the roof edge (plastic) garnish. The factory racks, as well as Yakima and Thule racks bolt to these points (with #6 metric bolts). Thule's adapter is based on a short length of their standard track.

I constructed my own rack with brackets made from 1 1/2" aluminum angle, paired with parts from an old Yakima roofrack. Others have made racks from angle steel, wood, etc.

One problem is that the spacing between cross bars is fixed at a rather short 27". And there have been a few cases of broken spot welds holding these mounting points to the roof.

 

[dyogim]

Got the feet and load bars installed finally. Next is to built the framing for the platform, approx. 4'x4'.

​

 

[dyogim]

Another budget install in progress. Here are a few pics of my home made roof rack and frame for the platform/basket. Still need to add one additional support bar in the middle and purchase a piece of 4'x4' wire decking. The wire decking is normally used on industial/warehouse shelfs that can hold well over 1k lbs. Don't plan on having that much weight up there. Here's a few pics.

 

[eugene]

I beleive the 'tracks' you piont out are where the bodt welds are. I noticed a few years back that truck cabs started being made like cars where they weld the sides to the roof and put the strip of plastic to cover them just like a unibody car. All of the SUV's and vans with roof racks I've seen have the racks mounted there as well since its two layers or metal spot welded together its the strongest point.

 

[dyogim]

I beleive the 'tracks' you piont out are where the bodt welds are. I noticed a few years back that truck cabs started being made like cars where they weld the sides to the roof and put the strip of plastic to cover them just like a unibody car. All of the SUV's and vans with roof racks I've seen have the racks mounted there as well since its two layers or metal spot welded together its the strongest point.

Mine had 4 layers and I'm glad I mounted the feet there.

 

[dzzz]

I beleive the 'tracks' you piont out are where the bodt welds are. I noticed a few years back that truck cabs started being made like cars where they weld the sides to the roof and put the strip of plastic to cover them just like a unibody car. All of the SUV's and vans with roof racks I've seen have the racks mounted there as well since its two layers or metal spot welded together its the strongest point.

The strongest points are at the pillars. It's good to get at least some of the rack on the B pillar. On a pickup like the one here the C pillar is the roll bar, but it's hard to use without extending over the bed.

I wouldn't block the hidden gutters. I also wouldn't drill a hole in a recessed shape designed to collect water.

On an "expedition vehicle" the best way may be to cage the vehicle by supporting the rack with columns extending to the fender and C pillar. This way gives rub protection to the vehicle and makes a big basket.

 

[dyogim]

Any mods, please re-locate this thread to the General Vehicle Modifications forum. I've asked another mod a couple weeks ago but, no response or change.

Otherwise, here's some updated pics of the roof rack/basket install. It's pretty much complete.

​