Topic: Want to add roof rack!

[Fowlhunter]

I need some help here with the pros and cons so please speak up and let me know what you think.
When I purchased the Ole girl I always wanted to add a roof rack but never did, I think it would make her look much better!  I could pick one up from the dealer or find one on Ebay, give me some feedback on installation.

Also, what are your thoughts of adding some kind of cross bars and or rack on the bed covers?

Thanks

[MyBigToy]

I'm the opposite of you, then. I specifically did not want a roof rack. They add an additional point for leaks, they decrease your gas mileage, they add noise to the interior, and you rarely if ever use them. We had a rack on our 2000 Exploder and never used it; the Enclave has a rack and we haven't used it so far.

I've not installed one but I've read through threads of people who did. I believe you'll have to pull the headliner out and you'll have to drill at least 4 holes in the roof. I like the rack on the bed covers idea better. I've seen several of those that I thought looked pretty usable.

Sorry I couldn't provide detailed instructions but at least I added my $0.02, for what that's worth.

[bluedevil]

Yep.  Pull out headliner, drill, grommets, seal.   Again in every other year.  I guess depending on the type of sealer and how is added it may last longer.


The rack on the bed sure is better idea.

Heck, even a Thule basket on the covers would be great.  You can fit lots of birds there.

[Ski Edition]

Looking at going the route of attaching one to the bed panels.  Even with a small ski rack on top, there is wind noise and I'm sure, some drag.  There was one for sale on TOS, but couldn't come to terms with the seller.  Would love to have a basket to throw coolers, etc in when we go camping.   

[oHIobellboy]

Anyone know offhand the weight limits on the bed covers? Something to keep in mind.

[Fowlhunter]

From the threads I've read the headliner doesn't need to be removed, there is a template that is used to locate the rack then holes are drilled in the roof and some type of bolt/well nut is attached then attach the rack.  From the threads I've read it doesn't appear to be that difficult.  I'm not sure of the weight rating, I thought I read 75lbs somewhere? I thought it would add to the look especially if I were to add a basket to the rack! 

[MyBigToy]

The weight limit on a panel is either 200 or 250 lbs. so if you have the rack attached to two panels you could load it up with 400-500 lbs without an issue.

[kklobe]

I have the factory rack on the roof so I can't speak on any install issues.  I also have a Yakima rack on the back and I can speak of install issues. 
The rack looks great and now that it is solid I use it.  Yakima (at the time I did mine a year ago) did NOT offer a rack system for the bed cover of the Av.  I used what I had seen online and found all of the part numbers to put it together.  I run a bike shop and I have installed racks on vehicles that were made for said vehicles.

The rack system on my Av, I could have pulled off with my hands once it was on.  I had to do some minor modifications to get it to stay put with any load on it.  I had to countersink small carriage bolts into the covers and then seal everything to keep water out.  But getting the rack on was a royal pain in the  to say the least.

If you put a rack, towers and load bars, on the bed, make sure they are specifically designed for the cover of the Av or you will have problems getting the towers to stay put - they will slide backwards in transit with a load.

Kevin

[Richie_Rich]

I've never used my rack on the roof, but that one BD posted looks cool.

I don't like the idea of putting a rack set up on the bed covers.
If I need to remove them, I'd have to take the rack off and store it.
I'm sure it would be more useful than the one on the roof though, but not worth the aggravation to me.

If my rack tuns up missing, I'll know who to go looking for.

[Fowlhunter]

You don't actually mount the rack on the bed covers, I don't like that idea because I need to remove mine so often it would be more of a pain in the  than it's worth.  I've seen threads where folks have mounted the rear cross bar to the location of the rear grab handle area and the front in the area of the vents just inside of the sails.  This way you could have a ton (so to speak) of weight mounted to the bed rack and not even touch the covers!

I'm not sure how often I would use the roof rack but I think it would make the Ole girl look more rugged plus I could go with a basket and possibly add lights!!

[HenryJ]

...I always wanted to add a roof rack but never did, I think it would make her look much better!  I could pick one up from the dealer or find one on Ebay, give me some feedback on installation.

Old post, I know.
Mine came without a roof rack. Adding one is no big deal. I purchased a used one from a Suburban and cut it down to fit.
Mark the holes once it is lined up , drill and add Nutserts. BTW, add tape to create a stop for the drill bit. You do not want to slip and drill through the headliner. Ask me how I knew that A little sealer on the insert and the threads of the screws when you install the rack to seal it. Pretty easy.

Mine received the safari basket and awning off my old truck.

[oHIobellboy]

Old post, I know.
Mine came without a roof rack. Adding one is no big deal. I purchased a used one from a Suburban and cut it down to fit.
Mark the holes once it is lined up , drill and add Nutserts. BTW, add tape to create a stop for the drill bit. You do not want to slip and drill through the headliner. Ask me how I knew that A little sealer on the insert and the threads of the screws when you install the rack to seal it. Pretty easy.

Mine received the safari basket and awning off my old truck.

I'm wanting to add one to mine too. How much did you have to cut? I'm assuming it was just the side rails you cut?

[HenryJ]

I'm wanting to add one to mine too. How much did you have to cut? I'm assuming it was just the side rails you cut?

You are correct. The two pieces of rail that I have left over are 41.5" long. Measure twice and cut once.
Matching the holes for the endcaps in the rails can be a challenge. Don't get them flipped and drill the spacing wrong. It can happen  The locator pin on the feet is offset to one side and is easily transposed.

I salvaged the rails from one rig that had no bows and one bow from each of two other suburbans to get a nice rack. lots of rolled rigs in that yard.

I have a Nutsert tool, but if you do not you can get a screw that is longer than needed , a good fitting hardened washer and a nut to install your Nutserts "on the cheap". Thread the nut on to the screw, add the washer and then the Nutsert. Insert it into the hole you drilled to fit snugly. Hold the screw and turn the nut to crush/install the Nutsert. Not as fast as the tool, but much cheaper. Permatex #2 a non hardening sealer works well to seal the Nutserts and the cap screw threads.
I bought 1/4-20 conventional Nutserts and 1/4-20 phillips pan head stainless steel screws to attach the rack. I thought that I had one to check for length, but I can not find one. Sorry. Measure the removed stock Torx head metric bolts for length. Slightly longer is better than too short. You need to fully engage the threads in the Nutsert.

The side rail center support is not "centered". That will be a tell tale indicator that it is not "factory".  Most will never know.



You will have to be the best judge of where it should be located fore and aft. Side to side is easy. I think the rear feet are about 3/4" from the sail panel plastic and the back of the front feet just about line up with the back of the sun roof.
Make sure that the bows are on and lined up. Triple check everything. Mark, center punch and drill a pilot for each hole. Take your time.

[oHIobellboy]

Well after lifting the Avy it just seems like a roof rack would look good up there. I've check eBay for used ones and am just too cheap to spend over $200 on something I can't see first when it's coming from a salvage yard. Going through the site's store this morning I used the link to JCWhitney and came across this one made by Proline.
http://www.chevyavalancheclub.com/customshop.php?goldencanmid=193658284&goldencancid=1654137

Anyone have any thoughts or experience with them?

[bluedevil]

Up to it?  drilling and silicone it?


I do like the basket better than the rack. 

[oHIobellboy]

Up to it?  drilling and silicone it?


I do like the basket better than the rack. 

Asking me if I'm up to modding? You should know better than that   

Just want the looks of the rack. I doubt I'd ever use it.

[Ski Edition]

Asking me if I'm up to modding? You should know better than that   

Just want the looks of the rack. I doubt I'd ever use it.

Love the look (wouldn't trade mine for anything), but 6+ years and I never used mine!  Waiting to put on my rear basket!  That may me an option.   

Just picture it with a couple of cross bars.  I can't afford any more drag with cargo on the top.  MPG's are a little skinny already!  Thought this would keep it steamlined!   

[oHIobellboy]

OK. We streamline yours by putting it on mine and patching the holes on yours.

[Ski Edition]

OK. We streamline yours by putting it on mine and patching the holes on yours.

If you still have some money and your painter is on-board, I don't see a problem with it!!   

[BooomerX]

Hey Ski where did you get that sail spoiler? That may be my answer to putting the Jeep light bar I got on my sails.

[Ski Edition]

Hey Ski where did you get that sail spoiler? That may be my answer to putting the Jeep light bar I got on my sails.

I bought it from a member that sold his AV.  If you google "Sport Wing", there are a couple of vendors out there selling them. 

[BooomerX]

Found one, thanks a bunch. I believe this will be the easiest way to mount the Renegade light bar I got and still be able to remove it quickly if needed for clearance into my garage.

[oHIobellboy]

Talk about getting excited. I called a salvage yard about 30 mins south of me and asked about a roof rack. Guy tells me, "Yup, got two of them. $100 each" I tell him, pull them off, I'm on the way. Sent a text to Fowlhunter letting him know I got a rack for him for $100. I get down there, go out in the yard with the guy. We take the one off real quick and head for the 2nd one. (Damn, I just realized as I'm typing this I forgot to look for that bumper plate for our member in the UK ) We get to the 2nd one and the whole dang roof is gone So much for getting two of them.
I started checking the part stores this morning for the nutserts that go in the roof. Nope, Nada, zip. They don't have them. I stopped in the local Fastenal store and whaddya know. We find them after digging around for about 15 minutes. Here's the link for them. http://www.fastenal.com/web/products/detail.ex?sku=0162802&ucst=t  $17 for 10 of them. Now if it would quit snowing I'd get this thing put on today. Garage is too low to try to put it on in there. Worse case scenario if I get really bored I can drive around the corner to the shop that did my work and do it there. The owner gave me an open invite to use floor space over there whenever there's room for me.

[Fowlhunter]

Do you have it on yet?  Is your  all puckered up just thinking about drilling your roof?  Pics please!

[oHIobellboy]

Do you have it on yet?  Is your  all puckered up just thinking about drilling your roof?  Pics please!

not yet. Gonna wait til I can do it outside. I've been up since about 5pm yesterday and don't plan on going to bed until later so I might be a little sluggish. I hate working midnights.

You know me, I ain't afraid of no drill.

[Richie_Rich]

You know me, I ain't afraid of no drill.

You should have seen the looks on people's faces when I took a jigsaw to the dashboard in my old Conquest to put slide out cup holders in there.
Then again when I cut the hole in the roof for the aftermarket sunroof.

Your truck already looks great, just one more to top it off ehh?

[oHIobellboy]

Your truck already looks great, just one more to top it off ehh?

Thanks Rich. It just looks  like something is missing up there. I thought about a sport wing but we use it for camping with the Avy tent (although we'll prolly use Twiggy's for the tent now) and I just don't know how much I would like a wing on there. I think they look great on other Avy's but I'm just not sure if I want to go that route. A luggage rack on a lifted Avy looks right at home though.

[Ski Edition]

I just don't know how much I would like a wing on there. I think they look great on other Avy's but I'm just not sure if I want to go that route. A luggage rack on a lifted Avy looks right at home though.

I like both!! 

[BooomerX]

OBB when you pulled the rack off the junker is the end cap on the front drivers side hollow or solid and does it come off without taking the rest of the rack loose? I'm wondering if I can go through it into the roof for running the wire for my light bar with a small hole under the end cap?

[oHIobellboy]

OBB when you pulled the rack off the junker is the end cap on the front drivers side hollow or solid and does it come off without taking the rest of the rack loose? I'm wondering if I can go through it into the roof for running the wire for my light bar with a small hole under the end cap?

I think it's hollow and I know it has a little clip that the side rail clicks into. I'll study that here a little later to see if that idea would work for you.

Here's a few pix Boomer. When I thought about it I only had my phone handy. Looks like you might get away with it after modding the cover a little bit. It might be less obvious going to the inside of the rack is why I took the pix with that side more dominant. The second pix is a close up of the end piece without the side bar in it so you can see the latch tab.

[HenryJ]

...I ain't afraid of no drill.

A little fear is good. You may already know, but I'll add it for any lurkers. Wrap tape around the drill bit and layer it up enough to create a stop so that when the bit grabs it doesn't suck through the headliner. Learned that one the hard way :(

Those Nutserts are available individually at the local TrueValue Hardware stores here. Another source is your local Au-ve-co dealer. I find their pricing much better than most, but like Fastenall , there are minimum quantities.

One more thing...this thread needs more pictures!

[oHIobellboy]

A little fear is good. You may already know, but I'll add it for any lurkers. Wrap tape around the drill bit and layer it up enough to create a stop so that when the bit grabs it doesn't suck through the headliner. Learned that one the hard way :(


One more thing...this thread needs more pictures!

Ithought of just putting a deep well socket along with a few washers if need on the bit to act like a stopper. I only need about 1/4" of drill bit I would think.

Once I get into the meat of the project, I'll do a "how to" complete with step by step and pix. 

[HenryJ]

Set the depth of the bit to the length of the Nutsert. On a few of the holes you will be drilling through the structure under the top skin.
Drill a small pilot hole first for every hole to be drilled. There are a couple that are very close to the edge of the under bracing and will be forced off center if you do not have a pilot drilled.

[oHIobellboy]

Set the depth of the bit to the length of the Nutsert. On a few of the holes you will be drilling through the structure under the top skin.
Drill a small pilot hole first for every hole to be drilled. There are a couple that are very close to the edge of the under bracing and will be forced off center if you do not have a pilot drilled.

Thanks. I'll make sure I do that. Gotta love it when someone else has done a mod before you and has good advice.

[HenryJ]

The feet on your rack are different than mine, so I can't be sure exactly where they might line up. It never hurts to be cautious and drilling a pilot is just good practice.
Much of what I learned has been from the "school of hard knocks". I've mounted more than half a dozen different racks on various vehicles now. All the fear is gone 

[oHIobellboy]

The feet on your rack are different than mine, so I can't be sure exactly where they might line up. It never hurts to be cautious and drilling a pilot is just good practice.
Much of what I learned has been from the "school of hard knocks". I've mounted more than half a dozen different racks on various vehicles now. All the fear is gone 

I do have an '05 sitting in the drive next to my '04 if I need a template. I've already taken measurements off of hers but it sure won't be too hard to line up.

[HenryJ]

Sounds like all checks are a "go"...countdown continues. All systems go!

[oHIobellboy]

60* here and dry today. The Avy got a wash and wax and the roof rack. Pix and write up tomorrow when I can get a better daytime shot. I will say this much. I wish I would have went to a dealer and bought the factory nutserts instead of the ones from Fastenal that I had to modify. From doing some more reading it looks like I could have saved a few buck too.

[oHIobellboy]

Linky
http://www.chevyavalancheclub.com/index.php?action=articles;sa=view;article=112

[bluedevil]

That's way cool obb

[dnice58]

excellent write up and a d**n good install

[BooomerX]

Rack looks good
If you ever add lights up there, I think the end cap down through the roof route is the best way to wire them.

[Fowlhunter]

Great job mike and awesome write as usual!   
The ole girl looks great, can't wait to see it in person.