So this is my first DIY, I hope it is understandable, and sorry for crappy cell phone pics. Anyway, I was tossing the idea around for a while and decided to finally go for it. I snagged an oem rack from a 97 limited in pick-n-pull.

Tools needed:
T25 Torx
Small flat head screwdriver
sharpie
DREMEL and cutoff wheel
cordless drill
set of high speed metal drill bits
Threaded nutsert tool
at least 6 inserts M6x1.0 I had extras just in case you mess one up
tube of silicone

grand total was less than $35, the rack cost $22 at pick n pull, inserts were $10, and silicone was left over on hand but is usually about $3


First step was to remove my end caps and take a measurement for how long. I wanted the "extensions" to be, 28 inches is what I settled on, any longer and the end caps wont sit quite flush.
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Then get the new rails and cut them down to size
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Install at least 2 cross bars to square up your new rails, I also popped up my sunroof a bit to make sure it was going to clear. (place your cross bars so as to not block any holes)
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With it set into place tape it down so you don't have any movement, and mark the center of all your holes(6 total)
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Helpful tip, start with a small pilot hole, then work up to your final size. Also mark the depth you need with tape on your drill bit, its a make shift depth gauge so you don't drill too far.
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I drilled holes in my roof? What was I thinking?!?! too late now...
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This is a threaded nutsert tool. Cheaper ones can be found for at DIY, but I have a buddy that works at a semi truck shop and he loaned it too me.
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Line your holes with silicone before inserting your threaded nutsert. This helps seal everything up.
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Installation is similar to a giant rivet.
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1 down 5 to go
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A full row installed
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A bit more silicone on the threads of the bolts to seal it up, don't want any leaks in your roof.
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Loosely install the new rack extensions, leave the bolts a bit loose till you have all of them started, then tighten everything down with the end caps in place on the front and it is done! Total time took about 2 hours, because I was taking my time measuring everything 3 or 4 times.
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And Job Done! All that's left is to try to explain to your wife what you just did because "your truck looks the same, did you even do anything to it?"
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This is awesome

Took it to a car wash last night, NO LEAKS! All was a success.

Nice work. I don't know if I'd have the courage to drill more holes in mine.

can you grab a pic of how close this was to your sunroof. I measured it out on my 4runner and thought the rail would be laying on the sunroof seal instead of the roof. It looks great tho! I'd love to do it myself.

Looks neat! I can appreciate the time and effort you put into this project.

I actually have a piece of track ready to do this on mine as well. I want to be able to mount my roof box farther forward.

Nice How-To!

-M

Those turned out nice. What rims are those? Tried scoping your garage but didn't seem updated.

A unibit is your friend for anyone that wants to do this.

Definitely not the same quality, but Amazon has a set of three for $7. They work good.

I will try to grab a picture for you as soon as I can. The only contact I had when I put it into place was the rubber seal under the rails barely touched the rubber seal for the sunroof, I was going to trim it if needed but the sunroof operates just fine and it doesn't interfere. On a side note, I never realized the sunroof is wider at the back than the front.

Thanks, I just put them on, from a 2005 SR5 sport. I bought them a member on here. Made the truck a lot newer over the old split 3 spoke style I had before.

@RockenAlex Here is a couple pics, it sits very close but mine operates smoothly past it. You can see the little bit of rubber I was going to trim but didn't end up needing to.
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Very tight, but looks good! Much appreciated man!

This is a great idea. I've been trying to figure out a way to cheaply do this, so thanks for sharing!