Using 8020 for the crossbars? We did something very similar for my son’s 4runner. Fun project.My DIY roof rack project is now in full swing. Used 1/4” MDF bender board to get the shape i wanted and transferred the shape over to 1/4” 6061 aluminum plate. I don’t have a band saw so i busted out the jigsaw with some metal blades and some Mobile one synthetic to help with the cutting. Now sand the edges to match and then mark out the holes for the crossbars. View attachment 2921936