Load Bar option for roof rack/cargo baskets

[Gordinho80]

Posting this in case anyone is considering a roof rack and looking for mounting options...

I have used 1" square aluminum tube as well as 1" round tube as load bars for my Yakima...


and


The square tube was MUCH better then the round, for sure. But still felt a little weak to me. I also used rather thin aluminum.

Well, scouting out some options, I came across a set of THULE load bars on craigslist for dirt cheap.



First impression... although a little worn, as they are used... these things look good. And man are they STRONG! I haven't mounted my rack to them yet, but I'm planning on doing so soon. I also have an idea for mounting to the tracks... that's staying top secret for now, at least until I can confirm/deny that it would work...

[HARDTRAILZ]

I have those Thule bars and they are fairly strong. I plan to use them as well, but didnt want to dick with it this winter. I actually just dug them out last night to get started on mounting them. The stock rails suck for mounting a roof rack, but it was the best option at the time.

PS...If you find a good way to get them on...SHARE PLEASE

[Gordinho80]

I'm fairly certain that what I have in mind would work very well. As does another member who has cleverly figured out what I've been planning. Should have something this weekend...

[HARDTRAILZ]

I had a few ideas. Something similar to JDs light bar mounting idea, drill straight through the factory side rails, and the other was to use a u bolt around the side rails.

[OregTrailBlazin]

I have the Thule Rack on my truck, I didn't end up using the rails, I wanted the rack as close to the roof as possible, so I welded some brackets directly to the rack, and made some T-Bolts to slide in the stock tracks....

[Gordinho80]

I have the Thule Rack on my truck, I didn't end up using the rails, I wanted the rack as close to the roof as possible, so I welded some brackets directly to the rack, and made some T-Bolts to slide in the stock tracks....

[OregTrailBlazin]

I have the Thule Rack on my truck, I didn't end up using the rails, I wanted the rack as close to the roof as possible, so I welded some brackets directly to the rack, and made some T-Bolts to slide in the stock tracks....

Aww yes.. the good ol pics...

[Gordinho80]

That is PIMP! I wish I had a welder... and could weld... LOL

[OregTrailBlazin]

That is PIMP! I wish I had a welder... and could weld... LOL

Thanks! ! Really, it was one of those very last minute things before my last trip down south, I had the rack givin to me, and not enough room in the rig, so I threw a few thing together. I have plans on building a full length rack.... One of these years !!

[Trail X]

Is that before or after you get the snorkel piped up?

[Philberto]

Thanks for the info on the square load bars being stronger vs the round ones. I had originally planned on going to round ones for ease of being able to use clamps, but will check out the LB50 bars from Thule now that I know they're stronger. Deflection is my key concern, so I want the most rigidity possible.

[OregTrailBlazin]

Thanks for the info on the square load bars being stronger vs the round ones. I had originally planned on going to round ones for ease of being able to use clamps, but will check out the LB50 bars from Thule now that I know they're stronger. Deflection is my key concern, so I want the most rigidity possible.

I wouldn't buy them from Thule, try the local metal supply now that Gordinho has givin you the measurements.. I would send you mine, but I already cut them up for something else..

[Gordinho80]

Check craigs... I got mine for $10...

[Trail X]

It's just a difference in material strengths between steel and aluminum support bars.

You can pick up 2 square steel tubes at HD or Lowes for probably less than $10, you'd just have to paint it. I prefer the aluminum over steel because it doesn't rust... I hate rust.

Another way to help this issue is by choosing a roof rack that mounts closer to the sides of the vehicle. You will induce less bending in the cross-support beams. For instance, Mario's Yakima rack mounts closer to the centerline of the vehicle than my Bajarack does. Any support beam will seem stronger if your rack mounts closer to the stock roof-rails (or whatever your mount is).

[Gordinho80]

This is true... the Yakima is rather narrow. The closer to the roof rails, the better...

[Philberto]

Excellent, seeing as how mine will extend approx 1" out from each end of the roof siderails, the mounting points will be exactly on the side rails... or however I mount it... need to get the ramp first to figure that out.

[MrSmithsTB]

Has anyone considered shallow strut? 7/8" deep, slotted or non, comes in 10' lengths, galvanized. We can cut it to fit, and either use 1/2 rigid strut straps or spring nuts with 2-hole rigid straps to hold the basket on.
images for reference:

[Gordinho80]

Finally got the rack back up using my new load bars. These things are VERY strong...

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[Trail X]

Did the channel nuts work out?

[Gordinho80]

I had to cut them down, but they're in there and they're awesome! You can kind of see them in 1 of my attachments...