Texas does get warm with summers going over 100 degrees pretty easy. But as for improper install of the sides; pretty simple to bolt sides to crossbars. It is a really simple design.
We are referring to an improper pressure of the front feet. Possibly due to too little pressure resulting in access movement "rattle" you were hearing prior to the metal on metal contact. My rack makes zero noise on even extreme washboard unless I have the tent attached in which cause some may be present but it is not from the front of the rack moving. This could be due to lack of explanation on our instructions which we are going to look into. This is not something we are going to brush aside either. We are working on a solution and are happy to provide all that have had problems with this our solution. We are going to make a short video to post here as well as use in an installation video in regards to the front feet to clear up any and all confusion.
To add, our original test set with these feet on Will's 4runner are not even glued and have yet to fall off. Is this possibly a rare case.. sure. Just shedding light on where we are coming from and how we are looking at this issue.
On the note about our side plates, 1/4" aluminum is about as thick as possible within reason. Prinsu uses 3/16" side plates, so in comparison, we are going overkill. We don't see the need for any support along the front like you have mentioned. This isn't to say that it wont make your rack more sturdy, it will, and it may help resolve your issue. With proper pressure on the front feet, you should have no issue without having to add the aluminum angle iron.
As mentioned above we are working on switching from a 5052 Aluminum on our side plates to a 6061. This is due to us receiving unusable rack side plates from our waterjet supplier that arrive warped beyond acceptable use. This is due to the manufacturing process of the metal. Yes, 6000 series is stronger, especially when not used for bending etc, but it is not the cause of your deflection up front, nor would it fix the aluminum from being prone to deflection side to side.
Overall, what I'm trying to say is that I think the feet may have been too loose on the racks that have had issues, and I think an easy solution until we find an adhesive that holds much stronger is to be sure that the pressure on the front feet is adequate to stop access movement at the front of the rack.
We also would like to apologize to anyone that has had this issue due to lack of clarity on our end, and if anyone else has experienced this we would love to hear about it here, or over email. Again we love feedback from our customers and its the only way to grow and develop our product.
Thank you for all your support as we work hard to create the best roof rack for our beloved 3rd Gen 4Runners.