80/20 with Stock Roof Rack

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what's the easiest way to get the oem cross bars? pop off cap, remove small torx on underside. do I need to remove the 2 t40 or whatever they are bolts? just making sure before I get started. if I remove those large torx bolts I need sealant right?
yes you need to remove the 2 larger bolts and the small torx on the underside or in my case inside of the rail. The bolts have plastic sleeves and didn't have any sealant on them, but probably would hurt to use some
 
yes you need to remove the 2 larger bolts and the small torx on the underside or in my case inside of the rail. The bolts have plastic sleeves and didn't have any sealant on them, but probably would hurt to use some
Weird. On my 03, I popped off the rear caps and fed on two additional crossbars and then popped the caps back on. 2 mins tops. No need to unscrew anything.
 
that def was not the case with mine. but got everything installed
I think 03 is also when the design of the stock rack changed slightly. More tapered.
 
OP and I both were removing the OEM crossbars, so rear towers have to come off
Just pulled mine again to install a prototype bar I’m playing with. Popped the caps and pulled the crossbar right out-

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So I’ve come close to ordering 3 bars + hardware for my 99 LC. I haven’t because I’m worried about the clearance. The only thing I put on top is 2 Malone kayak J cradles that attach with a bracket that goes over and under the bar.
Now I think I just need to get one or two extra factory bars.
What do you think?
 
if you need something to under the bar i don't think this will work for you...there's very little room
Mounted my Yakima ski racks on the 15 Series 8020 that mounts with a bracket under the crossbar. I built a low profile mount of strap aluminum and used expansion nuts on the ends. The clearance is very tight, but it does not touch the roof.

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Here’s my setup. The snowboard/fishing rod holders are by Front Runner. They work great on the 15 series but I’m not crazy about their lock/latch system. It’s a little janky and requires a key and some wiggling to open and close. I suspect the yakima or rhino versions would be better, but I do love that the FR mounts directly on the 8020 and are lower profile. The solar panel is held on with zip ties underneath. Doesn’t move an inch or rattle. I probably should come up with something more permanent but it’s working fine.
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Question guys, the T nuts that you all ordered that go into the factory rail slots, did they seem a little small for the slot size? I ordered the double set, 3355. I'm looking at maybe adding a washer to distributing the load to a greater area of the factory rail slot. see pics below. Does this seem like it should work fine to y'all?

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what did you decide? I think the washer would be fine, I did not use the double, I used the single and they turn themselves sideways and grab.
Question guys, the T nuts that you all ordered that go into the factory rail slots, did they seem a little small for the slot size? I ordered the double set, 3355. I'm looking at maybe adding a washer to distributing the load to a greater area of the factory rail slot. see pics below. Does this seem like it should work fine to y'all?

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what did you decide? I think the washer would be fine, I did not use the double, I used the single and they turn themselves sideways and grab.
Did you use this style 15 series and it worked in the stock rack slot?

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what did you decide? I think the washer would be fine, I did not use the double, I used the single and they turn themselves sideways and grab.

Yeah it seems the downside to the double is that they can't rotate like that, I used the washers though, installed it tonight, feels very solid. Taking it on a week long overlanding trip tomorrow so we'll see how she does.
 
Yeah it seems the downside to the double is that they can't rotate like that, I used the washers though, installed it tonight, feels very solid. Taking it on a week long overlanding trip tomorrow so we'll see how she does.

I also used a little blue loctite
 
Question guys, the T nuts that you all ordered that go into the factory rail slots, did they seem a little small for the slot size? I ordered the double set, 3355. I'm looking at maybe adding a washer to distributing the load to a greater area of the factory rail slot. see pics below. Does this seem like it should work fine to y'all?

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This was my solution to that problem. I didn’t feel great with the size of the nuts that came with the brackets. I made washers out of aluminum. I also tapped the end of the rails and put some bolts in to add more contact points for support.
 
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