So I googled Nutserts/Rivnuts and there are ton of varitations. Do you guys have a favorite? I plan on fixing my roof rack and also doing a tailgate like CDan has at some point. With those applications in mind--where should I order from and what size?
I'm partial to aviation hardware but for steel inserts you should be able get some from NAPA. I just looked at your location. Maybe you would be better off going the McMaster Carr or Grainger route for the rivnuts.
I dislike rivnuts, even the avaition hardware, they are only partially reliable in about a 1/4 or more of material, in thin sheetmetal they give poor performance.
Since they are to be used for the roof rack definetly go with steel inserts. The AL ones I mentioned will likely disappoint since they are not really designed for the loads of a roof rack and the potential for galvanic corrosion if not coated/treated well.