Roof rack cross beams

[Whtrnr]

After much pondering and wandering, (around hardware stores) I decided to make cross beams since the originals were missing from my 2000 4Runner. I wanted to go inexpensive as possible.

And, I wanted something a different than original. After seeing many great ideas on this site I decided on the following;

Items used:

10' Superstrut 1 5/8" x 7/8" - $17.34

2' Superstrut 1 5/8" x 1 5/8" - $7.94

4 - 3/8" galvanized bolts 1 1/2" long - $2.40

4 - 3/8" galvanized nuts - $0.88

4 - 3/8" galvanized washers - $0.88

4 - 1/2" nylon spacers - $2.60

Flat black spray paint - $5.97

Locktite - $6.47

Total = $44.48 plus tax

Using a hacksaw (no sawsall) I cut the 2' foot section of strut into four 4" pieces, drilled 2 - 3/16" holes into the sides to mount them to the rail. I also drilled 1 - 3/8" hole into the opposite side of each section to mount the cross beam to each piece.

I mounted the 4" sections to the rails using the 2 stainless bolts and the square nuts in the rails that held the original bracket to the rails. Since the bolts were too long I used the nylon spacers to take up difference. Prior to mounting these 4" pieces I pinched them in a vice so the cross beams would lay flat across them. (The angle of the roof causes an upward angle otherwise)

I then cut the 10' piece into 44" sections and mounted them to the 4" pieces using the galvanized bolt, washer and nut.

I still need to disassemble it, sand it down, paint it black and reassemble with Locktite.

I will probably use a shorter bolt and do away with the nylon spacer.

Here is what it looks like so far

 

[bwarren]

Nice! What screws did you use to mount the 4" strut to the factory roof rail? Are they just screw that secured the original factory crossbars?

 

[volkinator]

How bad does it howl on the highway? I used square tubing temporarily and man it was loud!

 

[19963.4lsr5]

Since your using conduit strut they make a special flat spring loaded nut that goes inside the Chanel. I use that stuff all the time.


Sent from my iPhone using Tapatalk

 

[Whtrnr]

Bwarren
Thanks for comment. I used the original screws that held the original bracket down. They are a little long so i might change to shorter ones and eliminate the nylon spacers.

Volkinator
It does howl some above 45 mph, so I will have to experiment with a fix. I've heard that wrapping a rope or bungee around it will help but we'll see.

19963.4lsr5
I did see the the spring loaded nuts, I just thought I be able to work with traditional nuts and they were cheaper.

 

[Mark_BC]

For the 4" pieces that attach to the rack, I see you used 2 bolts per side. But doesn't the original have only 1 of the square nuts? Where did the extra square nut come from? There are three of the cross pieces that rest on the roof, making for a total of 5 square nuts per side.

 

[Whtrnr]

The original mounting brackets (4) are held on with two stainless allen head bolts and 2 square nuts inside the channel. I also have 3 square nuts per side for holding the cross beams down. I will take pictures of my original mounting brackets

 

[3bears]

How bad does it howl on the highway? I used square tubing temporarily and man it was loud!

me too, or a aluminum ladder with open foot steps, man does the wind howl
I knew one fellow nail pounder who had to haul a ladder all the time. he hit the openings with spray foam

 

[Whtrnr]

Pics of the brackets I removed and reused the 2 stainless allen head bolts.

 

[Mark_BC]

Pics of the brackets I removed and reused the 2 stainless allen head bolts.

Oh that's a different bracket than what I've seen, there must be two types of OEM roof racks out there.

 

[Whtrnr]

Maybe someone could shed some light on whether these brackets are original or after market?
Thx

 

[Newb99]

Well this thread and your idea comes at a very good time for me. My son drove into an underground parking lot with the roof basket on and he broke the ends pieces or the roof rack. It is a Whispbar and from what I have researched so far I can not get the same model and pieces anymore. I am still looking though.

However in the mean time this is a great and quick fix!!

Thanks

 

[Whtrnr]

I began sanding and painting today on the cross beams. I discovered that where the strut had been cut it was beginning to rust very quickly.

I de-greased, sanded, cleaned, primed (self etching primer) and painted (flat black). I also removed and painted the 3 factory beams (the ones that touch the roof).

I am not very good at painting so I hope my paint job holds up.

 

[AssBurns]

I just got most of the fab work completed on my cross beams tonight and I happen to run across this thread. I had the OEM ones but one bent from throwing my 12' aluminum boat up there so I decided to made some new ones out of 1" x .120" wall tubing and some 1/8" plate. Bolts directly to the factory rails. I made it wide enough for my boat to sit upside down on the beams and easy enough to take down between trips. I also added some side plates with some tie down points for ease of securing the boat. Still got to clean them all up and paint them. I'll share more pics once complete.

Sent from my iPhone using Tapatalk

 

[Whtrnr]

Cross beams complete

I finally finished painting the roof rack cross beams and reinstalled them today. I like the way they turned out. Hopefully my paint job holds up.