Great write-up, thank you. Wish it was here when I bought mine last year.

Hey Tory, I got the rubber stripping. Did you use any adhesive or anything to keep it on or does the grooved slot hold it onto the leading edge of the rack?

The weatherstripping grooves or teeth are designed to grip the edge tightly. Installed by itself and holds on great.

Been through a few heavy rains down here in LA. Zero leaks evident in the headliner or anywhere else under the roof holes. I'm happy with my install and sealing washers.

That's great the hear. I recently bought all the hardware and sealer to do mine finally. Thanks again for the parts list, came in handy.

Great, glad I could help. Good luck with the install!

Any update on leaks with this install method?

I installed my rack about a year ago using Tory's awesome writeup and have no leaks whatsoever with my 4Runner out in the PNW elements 24/7.

Which reminds me I need to add some notes to the thread about my install, will chime in this wknd.

I have not seen any evidence of leaks, though I am in sunny southern California. I've been through a few heavy rainstorms and had my truck buried in snow up in Mammoth though.

I'll see if I can take off my kick panels and peek under the headliner sometime soon to make double sure there's no evidence of moisture.

Thanks for all the work and research you put into it. Going to be using this method this weekend to install my Frontrunner rack.

For anyone that is using this method that also had a hard time paying $36 for 12 washers, I found almost the same thing on eBay for $10 shipped. It is not marine grade 316 stainless steel but A2/304. I think it will be good enough for a roof rack though.

“304 is the most readily available grade of stainless steel and typically less expensive than its common counterpart, 316 stainless steel, which offers super corrosion resistance but is very similar overall. If your application isn’t exposed to aggressive chemicals and is instead only exposed to milder acids, then 304 stainless steel is likely the perfect fit.”

(12) M8 or 8mm Conical / Belleville / Cupped Spring Washers A2 Stainless Steel | eBay

Did you get a chance to look for moisture?

Those should work just fine! The quantities and prices on McMaster can be a bit inflexible. Usually the reason I prefer everything from them is because it's easier for me to order from one place (also I've never had McMaster mess up an order). No reason not to shop around though.

I did. I rinsed my car off this week and spent about ten minutes hosing the roof, including spraying the rack mounts directly. Then I went inside and pried down the headliner in the rear corners, as well as the driver's kick panel. Could not see any dripping or evidence of previous moisture buildup. I broke a trim clip doing the driver's side so I decided not to open the passenger at this time. I'm pretty confident that this is a good method for roof racks with flat mounting feet. I will continue to check to see how the rubber washers are holding up periodically.

So, I did not realize that Frontrunner racks have plastic spacers at the feet. Tried using the butyl tape and washers anyway and it was not good. The spacers don’t press against the washers evenly. Had to take the siderails off again and remove all the butyl tape and use silicone the next time. No other option really.

Not recommended for Frontrunner.

I’m not implying you suggested it would be, I should have investigated more before ordering $60 worth of supplies. Oh well.

I did end up using the metal washers though! Haha

Can you take some pictures of the mounting feet and hardware?