80/20 with Stock Roof Rack

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Fwiw- I bought 3 8020 1” x 2” black crossbars to convert my factory rack and then decided to replace the whole rack. If anyone is interested, especially in the Colorado front range, I’m ready to get these out of the garage. They’re in the packaging from the T-nutz store, complete with fasteners.
still have them? What’s the length?
 
Getting ready to place an order, I am a little concerned that the corner brackets may not be strong enough and would like some kind of additional mounting at the ends. Any ideas or options there?
 
Getting ready to place an order, I am a little concerned that the corner brackets may not be strong enough and would like some kind of additional mounting at the ends. Any ideas or options there?
Dude, with my set up I wouldn’t be the least concerned with 3 big dudes walking up there. That stuff is heavy duty.
 
I used some 10 series on my '99. Couple of U-bolts, washers and speed knobs and the Hi-Lift mounts up pretty solid. Going to work on an awning next.
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Something I have been playing with for a bit. Different sizes. Different spacingView attachment 1961053View attachment 1961054View attachment 1961055View attachment 1961056. Mounts up pretty solid.

What hardware (bolts and T-nuts) are you using to connect the 80/20 bars to the factory rails?


My '99 rack seems to be a bit off of the recommended 44" less 1mm sizing. It is consistent front/rear.
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Oops...
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On our 99 LX (short) rack, I'm getting ~46.5" inside the rails...
 
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I used these to connect the 15 series 8020 bars to the stock side rails:

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After reading this thread, I lean more towards this type of set up than other offerings. However, I would like to incorporate some longer 80/20 load bars for hauling canoes. If I replace my factory bars with 80/20, would there be some connection hardware that would be good to temporarily mount some longer 80/20 bars on top of the replaced factory bars. I’m trying to think it through, and I am guessing it would require to small spacers to raise up the height just a bit. Hope this makes sense, any help is appreciated.
 
After reading this thread, I lean more towards this type of set up than other offerings. However, I would like to incorporate some longer 80/20 load bars for hauling canoes. If I replace my factory bars with 80/20, would there be some connection hardware that would be good to temporarily mount some longer 80/20 bars on top of the replaced factory bars. I’m trying to think it through, and I am guessing it would require to small spacers to raise up the height just a bit. Hope this makes sense, any help is appreciated.

You could use one the gusseted 90 degree connectors like this or similar. They have a bunch of different options:
 
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There are myriad options for connecting, both to your factory side rails as well as connecting the extrusions to each other. It really depends on your goals. Also know that both 8020 and Tnutz offer tapping and machining options, so you could have the extrusion threaded for attachment using end plates. I’d go to their online store and LEGO together the setup you think will work. After all, people build cnc router table setups using these products , so nearly anything should be possble.
 
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Anyone figure out an eye hook that works on the series 10 bars?
 
Anyone figure out an eye hook that works on the series 10 bars?
I believe folks are using Frontrunner load rings with extrusions pretty successfully. I tend to tie stuff down (I’m an arborist, and my whole world revolves around rope systems) so I have yet to try accessories besides ropes and knots.
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Anyone figure out an eye hook that works on the series 10 bars?

I set up my 10 series bars with some M6 male eye-bolts from Amazon and M6 female t-nuts from 8020.net. I need to shorten the bolts, but in the meantime I'm just using some nylon washers to snug them up. Works great, and very cheap.

T-nuts: 3873
Eye bolts: Amazon product ASIN B07G15NF7C
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Looks a bit crooked in the photo for some reason, but no issues so far.
 
I believe folks are using Frontrunner load rings with extrusions pretty successfully. I tend to tie stuff down (I’m an arborist, and my whole world revolves around rope systems) so I have yet to try accessories besides ropes and knots.View attachment 2295744
I think these require 15 series bars not the 10 series...?
 
Guys I'm getting ready to order some parts from tnutz. One that that I hate is placing an order for something, getting into a project and realizing I dont have everything and have to place another order and wait for shipping. Does this parts list sound complete:

- 8020 15 series bars in various lengths. 1.5x3". I have measured across my factory rail from inside rail to rail and found that it goes from 46.25" down to 45".
- corner brackets - 4 per rail
- fasteners - 8 per rail. Am I correct in assuming that the same way I mount the corner bracket to the 8020 is the way I'm going to mount it to the factory rail? Looking at the posting above should I get the double t-nut to mount to the factory rail?

Also I want to mount rotopax, traction boards and a shovel up there. What else do I need? I think I want to use this shovel mount:
 
Wanted to share a revision I’ve done to mine for strength, ease and options. I added a 7’ 3/4x1.5 to each side running horizontal with the roof. Still a work in progress but wanted to share this option with my fellow diyers. View attachment 2368545View attachment 2368548View attachment 2368549
Great idea! I wanted the extra length, but didn't want to have to buy expensive towers and remove the stock rails. This seems like the right solution. Thanks for sharing.
 
Wanted to share a revision I’ve done to mine for strength, ease and options. I added a 7’ 3/4x1.5 to each side running horizontal with the roof. Still a work in progress but wanted to share this option with my fellow diyers. View attachment 2368545View attachment 2368548View attachment 2368549
So question is... What awning is that? How much does it weigh? And, does that setup feel more or less stable with the strengthening cross piece?

I want to get a 270* awning in the near future and would like to mount to stock rack on my 98 as I don't have the money to throw at a Gamiviti Expo++ quite yet. This was going to be a compromise for the time being until I get the Expo++.
 

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