Prinsu Install - Modified

[littlegreenmonster]

After lurching around here for a while and reading a lot of threads here and on the TW forum, i decided to get a Prinsu rack. After reading several threads on here, the one thing i definitely knew i wasn't going to be crazy about was its interface with the truck. I decided to build my own mounting blocks. It wasn't very difficult and i figured i would post the instructions here to help anyone who is interested in doing this themselves.

First step was to identify what i was going to make the mounting blocks out of. After doing some measuring i decided to go with t6061 aluminum. Generally strong and easy to work with. I decided the feet would be .75" wide and 1" tall. Each foot would be 5 inches long to provide enough mounting surface and area for a sealant. A 48" stick can be obtained from local metal distributors for about $50.

Step 2 - Cut up the metal into 5" sections and file/grind the edges smooth where the cut takes place. A band saw would have been ideal, but i used a chop saw with a friction blade as this is what i had access to.

Step 3 - paint the feet with white poly primer. i put them in place under each foot to ensure they were all the same. There was some variance. not much but some, so i marked them with a pencil and checked all the measurements. Then drilled each one twice with a 1/2" drill bit on a cheap harbor freight drill press at work.

Step 4 - Paint the feet as well as all of the hardware with duplicolor textured undercoating.

 

[littlegreenmonster]

After a quick dry fit i resized the Prinsu does not hug the roofline as nicely as i would have hoped, so i went back and made .25" spaces for the 4 corner feet. This cost me another $25 to get a 30" stick of .25" by .75" to make spacers the same dimensions as the feet.

after another dry run, this has mostly fixed the fitment issue. So now on to step 5 - assembly. These are the products i used in assembly

applied liberal amounts of sealant

 

[littlegreenmonster]

I then put rubber washers between the steel washers and the rack

Bolted it up

 

[littlegreenmonster]

finished installing the cross bars and tested for leaks today

I still have 3 cross bars left. Not sure if i will use them or not. I dont plan on putting a roof top tent on it. I use it for camping and some offoading and trail riding, but i would not call anything that i do "overloading" mostly some "Homedepotlanding" to get drywall or ply wood. I also have a large rocket box i can mount on here now with out it shaking like crazy at 80mph like it did on the OEM Roof rack.

I will say i am going to have to fix the gap in the front. There is more wind noise than i would like. Its not terrible, but more than there should be.

 

[Chocolate]

Nice rack!

 

[Yossarian]

Excellent work @littlegreenmonster This is exactly what I was envisioning doing with my rack, much better interface with the truck, great job.

FYI, you can source rubber trim strips from a variety of vendors to fill the gap between the fairing and your roof, I got mine from a specialty store in Denver. If you do this I recommend you put a strip of clear bra type of material under the trim to protect your paint.

 

[littlegreenmonster]

Thanks Yossarian. I was thinking about that or maybe even just cutting a new front panel.

 

[littlegreenmonster]

 

[littlegreenmonster]

I went ahead and drilled new holes to drop the fairing. Now there is only about a .5” gap. Maybe less. I am going to put a second cross bar in the front to creat more height. I am going to order a channel filler molding for the top one so it won’t have wind noise. Once I have that I will post an updated photo. This setup should provide some additional rigidity and mounting options as well.

 

[619TOY]

Lowering the front fairing also opens up a door for adding a single row (or double row) bug catcher

And still maintaining a pretty low profile...

 

[littlegreenmonster]

So I have been traveling a lot the last couple of weeks and have just now gotten time to work on the rack some more. I went and picked up a t-channel cover strip for about $4 from Grainger. it comes in 96" sections and fits perfect.

FAZTEK Cover,T-Slot,Black,for 5JA86,etc. - 5JB20|10AC7751 - Grainger

I still need to figure out what i want to do for weather stripping between the fairing and the roof of the truck. I also am going to fill the channels on the roof back in with the OEM weather stripping.

 

[Scylth]

@littlegreenmonster , would you pick a Prinsu if you started all over again?

 

[littlegreenmonster]

@littlegreenmonster , would you pick a Prinsu if you started all over again?

Yes. The install was more complicated than other brands, but i feel that this is really the best all around rack out there. Being made from the t-channel, the configuration options are infinite. You can get what you need to make your own attachments at Grainger or other industrial supply stores. All this being said i am not an "overlander". My truck gets used for road trips, offroading, camping, tailgating at football games, hauling kids, going to Lowes or Home Depot, and occasionally towing. I dont carry around a roof top tent and tons of "just in case" gear.

 

[littlegreenmonster]

I am going to the mountains in a few days so i decided to go ahead and put my rocket box on it. I decided to plasti-dip it white first though. On a previous trip i had a stick of deodorant melt due to it getting so hot inside. Hopefully this will help some.

right now i have it held on with the factory clamps, but not really that happy about how i have to space the cross bars tom make this happen. next project will be to make custom plates to attache it between the rails instead of around the rails.