OEM rack crossbar options

[Tex]

Looking for options on the OEM rack to add some functionality to it. I'd like to mount a few things to the roof, like fuel cans, traction boards, packout mounting plates, basket, etc. I'm not looking to add a RTT or anything big, and the existing rack is perfectly fine other than the limited functionality of the crossbars. As it is, the OEM rack can't do much of anything except hold stuff like skis or kayaks with ratchet straps.

Seems like my options are to mount a second rack on top of the existing rack or get a new rack entirely, both of which really miss the mark for me. Ideally, I'd like to just replace/add flat crossbars with t-slots/ cutouts to the OEM side rails, such as this:
https://lfdoffroad.com/collections/...ducts/ruggedized-crossbar-kit-5th-gen-4runner

I'm aware this won't directly translate to the Bronco as-is. The side rails only have two fixed positions for the crossbars with rivnuts, but it seems like that could be easily fixed by bolting on a secondary side rail inside to mimic the t-slot running the length of the 4runner's OEM side rail. Could even offset the side rails to sit low or flip upside down to have raised crossbars.

After looking for days to find something similar, I've pretty much decided it doesn't exist yet. Has anyone run across something like this for the Bronco?

Edit: Something like this would be pretty sweet too, just a bolt-in basket utilizing the existing bolt holes in the side rails:
https://westcottdesigns.net/product/toyota-land-cruiser-200-series-basket-roof-rack-inserts/

Sponsored

 

[Smokey142]

I’m in the same boat, currently I’m looking at building a 5x4 roof rack out of aluminum extrusion but I’m not sure how I want to attach it to the cross bars
I’ve also thought about using some 1x3 aluminum extrusion boards to just add extra cross bars but I’m still not sure of a good way to attach it to the rails without taking it to a shop and having them tig weld them

 

[Tex]

Yeah, you'd think there'd be better stuff available for the OEM rack by now. There's just not much you can do with smooth banana bars as far as mounting gear is concerned, and I'm not terribly interested in buying an entire rack to do what the OEM rack could do with better crossbars.

I probably wouldn't TIG them to the side rails, that's about as permanent as you get LOL. You could bolt the 1x3's to the side rail with rivnuts (the OEM rack has three positions each with two corresponding rivnuts). Might need to fab up a bracket with the right bolt spacing if you can't find any. It would be a fixed position for the crossbars, but if you're locating them yourself for a particular purpose then you shouldn't need to move them around afterward. If you do need to move them, well, another set of rivnuts and you're back in business.

Another option would be to fab up an adapter for the side rails. If you take a look at that second pic, the basket portion is held in by the two raw steel rails extending over the OEM side rails. Since the side rails on the Bronco have no t-slot cutouts to make mods and adjustments easy like a lot of OEM rails do, an adapter plate (they call it an insert) like that would make it easy to put what you want there. The inserts could be held in by the six rivnuts on the OEM side rail and provide either a cutout for carriage bolts to adjust the position of ruggedized rails, or to hold brackets to mount an entire basket as shown. Other bits could theoretically be added to the insert itself, like an air deflector/lightbar mount in the front, perimeter lighting, awnings, a ladder on the side, or universal mounting plates on the side for rotopax tanks or whatever you wanted. If you tied the rear of the rack with a mounting plate between the top and body like many already do, it would probably increase the weight rating for the OEM rack.

I've already emailed a few businesses to see if they'd be interested in making something like that, no luck so far. I'd use a service like SendCutSend which would make it really easy, but I don't know how to computer

Sponsored