So, I was teaching myself AutoDesk Inventor the other day and came up with this. It would basically fix Thule crossbars (cut down to ~44" from what I recall) to the standard SR5 rails. The upper piece has one end that fits into the slot in the rail and the other end fits into a Thule crossbar. Then, another piece is clamped below and fixed to the upper piece via a socket head screw.
The black is the thule crossbar, the white is a section of the T4R roof rail, and the gray are the parts I'd have machined.
Taking a quick look at the spacing between the rail and the roof, I realized that the socket head screw should go through the top section and thread into the bottom section instead of how I drew it up.
Basically, I think this would give me a pretty elegant solution to getting Thule crossbars, to fit all my attachments, on my 4Runner roof without having the huge Thule feet. I'm going to call around and see how much it will run me to have 4 of these machined and get more precise measurements (I was ballparking when I first drew it).
Thoughts? Should I go w/ this setup or the Thule feet? Another engineer that I work with was telling me that there is a company that makes pretty generic shaped steel blocks in all kinds of different sizes that would minimize the amount of machining I'd have to do on these, so I could possibly machine them myself.
I'm totally in love w/ Inventor, btw. What a fantastic modeling tool!