I was looking at roof racks and $1000+ seemed absurd for what amounts to some extruded aluminum and bolts.
I realized that the crossbars on most of these racks are just t-slot extruded aluminum (80/20) that you can buy for about $20 each already tapped, cut to length, and anodized. I bought 12 of them at 47" long each from a company called TNutz, though there are plenty of other places to buy.
For the side bars that hold it all together, I used 2" tall, 1/4" thick aluminum bar. The only real fabrication required is cutting the 2" aluminum bar and drilling the holes.
Video here:
Images with explanations here:
This was for my 5th gen 4Runner, so the 460 dimensions might be a little bit different.
I realized that the crossbars on most of these racks are just t-slot extruded aluminum (80/20) that you can buy for about $20 each already tapped, cut to length, and anodized. I bought 12 of them at 47" long each from a company called TNutz, though there are plenty of other places to buy.
For the side bars that hold it all together, I used 2" tall, 1/4" thick aluminum bar. The only real fabrication required is cutting the 2" aluminum bar and drilling the holes.
Video here:
Images with explanations here:
This was for my 5th gen 4Runner, so the 460 dimensions might be a little bit different.