Hey dude, i just removed mine and happy to see it live on with another 80! I'll shoot you a PM
Removing factory roof rack
- Thread starter Beau Diddly
- Start date
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Anyone have the exact specs of the original screws for the rack feet and the ribs? I have a collection of misfit screws up there now, some rusting. Pics and measurements would be great. I’ve seen other posts that these are 5mm x 0.80 (??? length may vary in feet and on ribs) but seems like what remains of the nutserts may only take something resembling a wood screw. At least that’s what the PO left in there. 
You ever get it dialed in? I just ordered some hardware for the main rack. You figure out anything for the middle ribs?Anyone have the exact specs of the original screws for the rack feet and the ribs? I have a collection of misfit screws up there now, some rusting. Pics and measurements would be great. I’ve seen other posts that these are 5mm x 0.80 (??? length may vary in feet and on ribs) but seems like what remains of the nutserts may only take something resembling a wood screw. At least that’s what the PO left in there.
This is the hardware from Mcmaster I used to cover up the holes on all 4 corners of the rack itself. The middle ribs are still on my roof as I opted to keep them. Mcmaster has some really quality high end hardware.
This McMaster shopping list is very similar (possibly identical) to the kit that Wits End used to sell for plugging the holes. I bought the Wits End kit a few years ago before the company closed and it's been on my truck ever since with good results. You can enhance the sealing of the rubber washer with a little bit of 3M strip caulk if you're paranoid about water getting in. I used the strip caulk on some of my holes and not on others because I decided it was more trouble than it was worth. Maybe someday I'll remove the plugs and discover whether with or without worked better! I had a couple bad / corroded riv-nuts and I removed them through careful destruction / cutting and replaced them with the riv-nut tool linked below before plugging all the holes with bolts and rubber washers.
Astro 1442 13" Nut/Thread Hand Riveter Kit https://www.amazon.com/dp/B003TODXQW?tag=ihco-20
The riv-nut tool is pricey for a one-time use for rack removal, but it has come in handy for mounting other accessories including tie-down points in the cargo area and fuse blocks and relays in the engine bay.
My paint job looks like crap I know, but at least it's not rusty 
I’m considering removing everything myself and getting real western with it. I’m not trying to preserve this thing in a time capsule…. That’ll be for the next one I get, I plan on beating on this one.
I have not tackled this yet but still on my list. Interestingly I was able to purchase the nutserts from Toyota but no other hardware, so I am still piecing this together. I’m in the “save the roof rack “ camp so I will be looking to replace/upgrade the attachment hardware at sone point.