I used the 1" square tubing like the OP, and added an aluminum L bracket on top of it. I used longer bolts to go thru both the L bracket and the square tubing, no welding, but may do that in the future since I have a TIG welder.

I like the extra lateral stability the L bracket provides and I used the wing nuts to make removal quicker/easier. This way I can leave the supports on and take the rack off. I was thinking of maybe putting some cross bars up for mt. bikes, or whatever.

It's not hard, but a little tedious when it comes to lining up all the mounting bolts. By the way I used angled head bolts and countersunk the holes so they are flush.

Hope that helps. Let me know if you want to know what hardware to get, I went to Ace hardware about a hundred times figuring it all out and would happily help you avoid that!

If you want to list some hardware that would be great. I think we had the same idea in mind, you just made it happen .

As for the 1" tubing.. I meant to ask what thickness aluminum did you guys use? I'm thinking of the 1/8" instead of 1/16", same for angle.

Can someone confirm the aluminum tube size/thickness? I assume it's the 1/8 but figured I'd ask what the others are doing. I'm hoping to have all this done by next weekend.

Here is what I used



I got it from Home Depot.

I got a curt with the extension, but I should have done what you did and doubled down. I like what you did. After I repaint my 4Runner, I’ll have to extend it more.

I coated my rack in Rustoleums truck bed liner too for extra protection. This rack has way less rust issues than the Cabelas brand I had prior.

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I think i have 1/8 and it was a bit overkill.

Edit: confirmed its 1/8, i probably would have gone with 1/16 if i did it again.

Overkill in what regard? I thought 1/8 was too thin haha.

I've had quite a bit of weight up there and the 1/8 thick tubing doesn't budge at all, I'm pretty sure 1/16 would be the similar. Your roof would probably collapse from the weight before anything happens to the tubing.

Toy2play, what light bar are you running on the front of your Curt rack?

Its a cheap no name from Amazon. In reality i dont use it a lot. The glare from the hood is kind of annoying for me so I use two hella 500's converted to HID and two flood lights that are near the front bumper for my offroad night excursions. I dont find myself on the trails at night much though.

Thanks for the reply. Do you recall what length bar it is? With the Curt rack listed at 37" wide, I'm guessing in the 30-32" range? This is exactly the type of light bar/mount system I'm looking for, if not the exact brand/model.

Went out and measured it, 31.5" across. I want to say they advertised it as a 32 inch, but i cant remember.

So i’ve had mine operational for almost 2 years now. It’s been on several extended trips loaded to the gills.

1.) weld it together instead of using the screws.
2.) paint the whole rack in rustoleum or similar. I sprayed on a layer of rust reformer followed by Rustoleum semigloss black.




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I got this today! Im going to see if it fits. Its off brand curt rack already extended 64”. And bout another extention

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Nice I use the very same green boxes as you. Keeps the dust and water out, been using them for years. Rack looks great too.