Thule Motion XT on GX460 Factory Crossbars – Clamp Clearance & Modification

[iT4RZ4N]

I’ve been meaning to put a roof box on my GX for a while, but I was unsure if the factory crossbars would work.

I’d seen a few posts on Reddit and other forums mentioning the very tight clearance between the Thule PowerClick clamps and the GX roof. One person even mentioned trimming the clamp feet, but I could never track down that exact post.

I decided to give it a shot myself, and the solution seems to work.

Here’s what I did:

• Installed the box on the factory crossbars.

• Marked where the clamps closed and identified the excess portion that could be trimmed.

• Trimmed about 1/2" off the lower end of each clamp foot.
  • This section doesn’t contact the rails, so I don’t believe it affects safety or strength.

• Applied a small piece of PPF under each clamp location as extra protection.

It's hard to capture the exact clearance with pictures, but it's definitely more than before. In the worst case, I could trim a little more if needed.
There is a bit of flex when the box is loaded (I haven’t done a full road test with a loaded box yet), but the clamps now seem clear of the roof, and the box has an extremely tight fit to the rest of the truck.

 

[Splat]

I've also got a Thule Motion XT - XL, but in place of the stock crossbars, I went with Yakima EZ Rider towers and the Yakima round bars.
This gives me plenty of clearance. And like you, the crossbars and box are rock solid.

 

[r2m]

I've also got a Thule Motion XT - XL, but in place of the stock crossbars, I went with Yakima EZ Rider towers and the Yakima round bars.
This gives me plenty of clearance. And like you, the crossbars and box are rock solid.


View attachment 3969199View attachment 3969201

View attachment 3969202

Did you get three sets of uprights for three cross bars?

 

[Splat]

Nope. Only 2.

 

[bryanle96]

Never had an issue with my Motion XT on stock cross bars. Didn't have to modify anything

 

[ScoMey]

. ..Had this Thule Force 3 XL Monstrosity mounted to the factory crossbars with no clearance issues... and we put heavy stuff in it like a Clam shelter, any number of other heavy bags of stuff that we take with us...

 

[century]

Do you think converting to an old-style u-bolt clamp system would be a good solution to using a box on the OEM bars? I was thinking it might be a bit stronger than cutting the clamps.

 

[iT4RZ4N]

Do you think converting to an old-style u-bolt clamp system would be a good solution to using a box on the OEM bars? I was thinking it might be a bit stronger than cutting the clamps.

View attachment 4009995

Oh yeah, I bet that would work pretty well. Definitely not as quick to take on and off, but you would have a lot of clearance.

 

[Ralo]

Never had an issue with my Motion XT on stock cross bars. Didn't have to modify anything

View attachment 3969637

Which size box is this?

 

[bryanle96]

Which size box is this?

Thule Motion XT L

 

[dwally21]

I’ve been meaning to put a roof box on my GX for a while, but I was unsure if the factory crossbars would work.

I’d seen a few posts on Reddit and other forums mentioning the very tight clearance between the Thule PowerClick clamps and the GX roof. One person even mentioned trimming the clamp feet, but I could never track down that exact post.

I decided to give it a shot myself, and the solution seems to work.

Here’s what I did:

• Installed the box on the factory crossbars.

View attachment 3968954

• Marked where the clamps closed and identified the excess portion that could be trimmed.

View attachment 3968955

• Trimmed about 1/2"off the lower end of each clamp foot.
  • This section doesn’t contact the rails, so I don’t believe it affects safety or strength.

View attachment 3968959
View attachment 3968961

• Applied a small piece of PPF under each clamp location as extra protection.

It's hard to capture the exact clearance with pictures, but it's definitely more than before. In the worst case, I could trim a little more if needed.
There is a bit of flex when the box is loaded (I haven’t done a full road test with a loaded box yet), but the clamps now seem clear of the roof, and the box has an extremely tight fit to the rest of the truck.

View attachment 3968960

What size Motion XT is this? I'm looking at an XL but wanting to ensure it isn't too long.

 

[dwally21]

What size Motion XT is this? I'm looking at an XL but wanting to ensure it isn't too long.

Never mind, I'm an idiot and you answered directly above.

On the other side, do you think an XL would be too/comically big?