Replace stock roof rack rails?

[NathanOfSeattle]

My friend gave me a nice roof cargo box which "fits" my 4runner, but my trunk hits the back of the roof cargo box. I tried moving the cross bars for the stock roof rack as far forward as they can go. And there's no way to change the mounting positions on the cargo box itself. How hard, and if possible, would it be to replace the stock roof rack rails with something longer? What sort of tools would I need to attach a longer roof rack rails? Thanks for your help!

 

[glenyoshida]

My friend gave me a nice roof cargo box which "fits" my 4runner, but my trunk hits the back of the roof cargo box. I tried moving the cross bars for the stock roof rack as far forward as they can go. And there's no way to change the mounting positions on the cargo box itself. How hard, and if possible, would it be to replace the stock roof rack rails with something longer? What sort of tools would I need to attach a longer roof rack rails? Thanks for your help!

The only thing holding down the roof rails are torx screws. Seems like it would be reasonable to drill new holes in the rails to move it forward a few inches. It would be a good idea to use silicone or something in the screw holes when putting the screws back in or you may find a leak next rain.

 

[NathanOfSeattle]

I need more than a few inches. I'd like to possibly get new roof rails that are like the stock ones, but longer. Is there such a product?

And how do I drill into my roof? I'm not that mechanically inclined so I don't want to be drilling into my roof without knowing what I'm doing.

 

[glenyoshida]

I need more than a few inches. I'd like to possibly get new roof rails that are like the stock ones, but longer. Is there such a product?

And how do I drill into my roof? I'm not that mechanically inclined so I don't want to be drilling into my roof without knowing what I'm doing.

I've never heard of longer aftermarket roof rails.

The roof is sheet metal welded on to cross braces. You'll likely need to find the next cross brace to set the next hole or you'll likely end up denting your roof with any like of weight load. Actually drilling the hole is the same as drilling any other sheet metal but you'll need to partially or fully drop the head liner so you have space to work. In order to drop the headliner you'll need to remove the grab handles as well as the A, B, C, & D interior pillar panels. The B,C & D interior pillar panels won't come out without removing the sill plate panels. I think you'll find it easier to partially drop the head liner instead of removing it completely. Once you have the head liner dropped you can drill your new holes and use a thread setter so you have something to screw into. This is a freaking cool tool for just the thing. Without this you'd probably have to try and weld a nut. It's a lotta work. Is the roof rack worth it? Got any pics? I wonder if you'd be better off selling it and then buying a rack that fits.

Link to Marson Thread Setter on Amazon $89 Shipped

 

[NathanOfSeattle]

I've never heard of longer aftermarket roof rails.

The roof is sheet metal welded on to cross braces. You'll likely need to find the next cross brace to set the next hole or you'll likely end up denting your roof with any like of weight load. Actually drilling the hole is the same as drilling any other sheet metal but you'll need to partially or fully drop the head liner so you have space to work. In order to drop the headliner you'll need to remove the grab handles as well as the A, B, C, & D interior pillar panels. The B,C & D interior pillar panels won't come out without removing the sill plate panels. I think you'll find it easier to partially drop the head liner instead of removing it completely. Once you have the head liner dropped you can drill your new holes and use a thread setter so you have something to screw into. This is a freaking cool tool for just the thing. Without this you'd probably have to try and weld a nut. It's a lotta work. Is the roof rack worth it? Got any pics? I wonder if you'd be better off selling it and then buying a rack that fits.

Link to Marson Thread Setter on Amazon $89 Shipped

Thank you for your detailed explanation. I think the choice is obvious now. no the roof cargo box is not worth it. I should sell it and look into getting one that allows adjustment on the cargo box itself (i.e., moving the mounting points on the cargo box backwards so that the cargo box can be moved forward to gain more clearance for my trunk), since I've already moved the cross bars forward as far as they will go.

 

[glenyoshida]

Thank you for your detailed explanation. I think the choice is obvious now. no the roof cargo box is not worth it. I should sell it and look into getting one that allows adjustment on the cargo box itself (i.e., moving the mounting points on the cargo box backwards so that the cargo box can be moved forward to gain more clearance for my trunk), since I've already moved the cross bars forward as far as they will go.

No prob. That's one of those things that should be a lot easier lol.