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Old 08-25-2016, 08:48 PM #1
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Inexpensive Full Length Roof Rack (Curt Rack)

I've received a few comments on my rack I built out of the Curt Rack that you purchase on Amazon for fairly cheap. I figured that maybe a few more people might be interested in this set up, and for about $250, it's a great way to get a full length roof rack on top. You will need to purchase the Curt rack(https://amzn.com/B004O844DS ) and 2 extensions(https://amzn.com/B004O844EM).

The rack measures about 88" x 39"x 6" in total. I went down to the local metal yard and purchased 1"x1" aluminum square tubing that I cut to about 81". I wanted to save on weight so I went with aluminum, steel works fine. It is possible to exclude the tubing and directly mount the rack to the stock rails. The tube allowed the rack to sit high enough so that it wasn't laying on top of the roof, and added some additional strength.

I used the stock slider nuts that were in the rail to bolt the rack and tubing to the roof. Since it has been a long time since I did this I couldn't recall what I used, another member confirmed @NYSLC93 did use the following hardware and worked fine. 10 M6 bolts either 60-65mm(2.5'") in length should work.

For the front legs I used a couple chair foot pads and coupling nut that you can purchase at Home depot, and screwed them onto a bolt with a couple nuts as stoppers(check photo). I used double sided tape directly on the roof and then twisted the pads until they were at the correct length and actually works great.

Drilling the holes and lining the bolts up was the most difficult part when installing the rack. I first measured the distance from where the tubing will sit on the rails to where the slider nut in the rail is located. I evenly spaced the 5 slider nuts from each other and marked these positions on the tubing. With the curt rack and tubing off the runner, I clamped it together, flipped it upside down and drilled the 10 marked holes which will be bolted to the slider nuts in the stock rails. I drilled 2 additional holes in the front for the legs. It might be wise to drill out the holes a little bit bigger so the 10 m6 bolts will line up easier. Because the stock rails do bow a little bit, I used some washers in the front and back to get the rack to level out.

In the front I did weld the aluminum to close it up, but you do not need to do this. I wanted to play around with the welder. I found some end caps off ebay or amazon that close up the rack nicely. You can use 4 of these to close it up if you would like. Something similar to this: https://amzn.com/B005QNBN0W

I've had this rack for a couple years and it has held up well. Sunroof opens with no problems. The only thing I would watch out for on this type of rack is rust. Metal items tend to rub off the paint easily and this rack will rust quickly if you're not on top of it. I touch up any exposed metal with touch up paint, and its held up well. Also there are some good mount points to add various items; shovel, lights, hi lift or any small things you an think of.

Obliviously there's a difference between a $250 and a $1000 rack, but for what I need, this fits the bill perfectly. I have had quite a bit of weight up and it's held up well. If money is stopping you from getting a full length, or you don't have a welder to make your own, this may work out better for you.
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Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_172756-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_172741-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160811_182229-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_172808-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_172914-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_182652-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_172946-jpg  Inexpensive Full Length Roof Rack (Curt Rack)-img_20160825_172907-jpg 
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Last edited by Toy2play; 08-26-2016 at 11:11 AM. Reason: words
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Old 08-26-2016, 10:01 AM #2
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Awesome, thanks. I got a Curt rack off craigslist for cheap, and now seeing this I'm going to do the same thing with just one extension.
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Old 08-26-2016, 11:06 AM #3
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Quote:
Originally Posted by BoomSticks View Post
Awesome, thanks. I got a Curt rack off craigslist for cheap, and now seeing this I'm going to do the same thing with just one extension.
The width of the Curt rack is perfect for our rails. Imo, it looks much better with a lower profile than stacked on the stock cross bars. One extension lowered down will look great on yours.
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Old 08-26-2016, 11:38 AM #4
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I call mine a 3/4 rack, curt with one extension

like the way you dropped it down, think I will do the same
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Old 08-26-2016, 05:09 PM #5
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Quote:
Originally Posted by 3bears View Post
I call mine a 3/4 rack, curt with one extension

like the way you dropped it down, think I will do the same
Can you post a pic of the "3/4" rack? I'm assuming it doesn't cover the sunroof.
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Old 08-26-2016, 11:08 PM #6
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Here's a pic of my Curt with one extension. Just a couple inches over the sunroof.
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Old 08-27-2016, 12:12 AM #7
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Quote:
Originally Posted by ScubaS View Post
Can you post a pic of the "3/4" rack? I'm assuming it doesn't cover the sunroof.
Here is one of the other 4runners in the family with 1 extention instead of 2. This is on stock cross members, and shows the difference in height.
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Old 08-06-2017, 10:16 AM #8
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Glad I found this old thread! Looking for a budget rack, and I hate the tall look. I'd like low profile, if I mount it directly to the rails without the square tube, will it contact the roof?

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Old 08-06-2017, 01:20 PM #9
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Awesome,while i really like the more expensive racks its just not feasible to spend 1000 bucks,i can save my cash for a arb fridge.
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Old 08-06-2017, 04:36 PM #10
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Quote:
Originally Posted by Coopsdaddy View Post
Awesome,while i really like the more expensive racks its just not feasible to spend 1000 bucks,i can save my cash for a arb fridge.
Exactly, I'm kind of having fun building a functional budget truck. I'm not going to spend thousands on a truck I paid $1,200 for, I'll save that for the G8.
The classified section here makes it easier, lol.

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Old 08-07-2017, 10:06 AM #11
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Quote:
Originally Posted by cstmg8 View Post
Glad I found this old thread! Looking for a budget rack, and I hate the tall look. I'd like low profile, if I mount it directly to the rails without the square tube, will it contact the roof?

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I am doing similar thing with a Rola rack. I needed to space it up a little to get it to clear the roof. There is also an adjustment to make as the roof is not level. I spaced the back up a bit to lower the front.
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Old 08-07-2017, 10:15 AM #12
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Great thread - I'm an Amazon who-re, so I appreciate it.

Once I get my custom storage box installed this will be next. Thanks - I may wind up PM'ing you a few questions.
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Old 08-10-2017, 06:15 AM #13
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Mine showed up yesterday:


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Old 08-10-2017, 12:21 PM #14
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Any info on your awning and brackets.
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Old 08-10-2017, 08:15 PM #15
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Quote:
Originally Posted by Coopsdaddy View Post
Any info on your awning and brackets.
Op hasn't posted in a year, but a quick search will bring up a few budget awning setups.

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