Well I finished the last project up on my list before our upcoming trip...
I wanted to carry extra fuel this year. We have had issues in the past (usually with a trailer) with the fuel gauge getting wonky at the wrong time, and then conviently fixing itself before we get it home to diagnose it. We are also planning to take a few more remote "roads" this year and with the weather factor at play, a few extra gallons wouldn't hurt. So I picked up a pair of 2 gallon Rotopax cans. I wasn't 100% sure how or exactly where to mount them at the time, so I didn't buy any mounts until I had made a decision.
Saturday I finally came up with how I wanted to do it and the only place I could find the 1" x 1" square tubing neglected to tell me they stored it outside in the rain, so the frame work took a LOT of clean up. Originally I had thought about building my own mounts but after the bed, the fridge mounts, new drivers seat foam. and a bit of maintenance i was getting tired and running out of time so I was all set to give in and buy the Rotopax mounts but of course 4wheel parts was out of stock on them. So I was back to making my own.
the result:
I ended up just replacing two of the stock cross bars with my part and securing it with just regular bolts rather than the tie down points the stock cross bars use. I know my method isn't quite as quick to remove as the Rotopax version, but it was cheaper, available with out leaving the shop, and does provide a bit more security than the standard mount that they sell.
If you are thinking of doing this, I'll warn you ahead of time that the roof is not nearly as flat as it may look. My 1" x 1" square tube is actually scalloped at the center up to 1/2" for clearance. When I welded the new material in to the cut outs, I managed to tweak it a bit more (in the right direction thankfully) to give even a bit more clearance.
Sorry for the crappy cell phone pics, but if they were good pics they would still be on the camera and not posted yet anyway.