Terrapod
New member
Howdy Folks...
Been on this forum...mostly as a lurker learning about my 4Runner. But at home, I am an industrial designer and an inventor of sorts. Simply put, I love tinkering.
Seeing all the ridiculously expensive solutions out there for racks made me think about another potential solution. But instead of offering it for sale, I prefer help those do it themselves.
Now...with that said - A disclaimer. I am not a manufacturer. I am not a professional mechanic. By doing this - you are on your own. Know that I am not responsible for what you do to your vehicle.
So here goes:
THE IDEA:
JUMP TO THE FABRICATION HERE: Crossbar fabrication Post
On my personal off road trailer. I built an aluminum extrusion based rack. It uses the very same rails that are on the Prinsu aluminum 4runner roof rack.
I was curious if the rails fit the height and space needed between the rail and curvature of the roof.
Here is the test fit with a total clearance of approx 1/2"
Next I worked up a design that allowed an easy installation while also providing a robust mounting option. The solution is an aluminum mounting plate adapter that bolts directly to the crossbar with 1/4-20 bolts that have been countersunk into the mounting plate.
The mounting plate is then bolted to steel plates tucked into the stock rail tracks. This is similar to the stock Toyota crossbars. The plan is to maintain a flush surface at the top of the OE rails and the crossbars.
Here is the design (side elevation):
Been on this forum...mostly as a lurker learning about my 4Runner. But at home, I am an industrial designer and an inventor of sorts. Simply put, I love tinkering.
Seeing all the ridiculously expensive solutions out there for racks made me think about another potential solution. But instead of offering it for sale, I prefer help those do it themselves.
Now...with that said - A disclaimer. I am not a manufacturer. I am not a professional mechanic. By doing this - you are on your own. Know that I am not responsible for what you do to your vehicle.
So here goes:
THE IDEA:
JUMP TO THE FABRICATION HERE: Crossbar fabrication Post
On my personal off road trailer. I built an aluminum extrusion based rack. It uses the very same rails that are on the Prinsu aluminum 4runner roof rack.
I was curious if the rails fit the height and space needed between the rail and curvature of the roof.
Here is the test fit with a total clearance of approx 1/2"
Next I worked up a design that allowed an easy installation while also providing a robust mounting option. The solution is an aluminum mounting plate adapter that bolts directly to the crossbar with 1/4-20 bolts that have been countersunk into the mounting plate.
The mounting plate is then bolted to steel plates tucked into the stock rail tracks. This is similar to the stock Toyota crossbars. The plan is to maintain a flush surface at the top of the OE rails and the crossbars.
Here is the design (side elevation):
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