I am installing a roof rack accessory that Thule calls "Hullavator"
It is, of course, designed to be installed on Thule 1.25" x .75" cross
My setup uses 1.25" crossbars and there is about 5 inches where the
racks join the bars and it's wider.
Excess vertical (1.25" vs .75") is not a concern because Thule offers
two mounting methods: brackets/clamps for the 3/4" bars and vertical
bolts for it's fancy-schamcy alu "Aero" bars... and I'll do that, just
with longer bolts through the 1.25" SS box.
Couple pix where I dummied up the install by padding the Hullavator base
so it rides on top of the cross bars and does not have to contend with
the wide area (highlighted with red tape in the second link):
My intent is to take a grinder to the mounting brackets and remove the
lips where they contend with the rack joint --- grinding off that 5
inches -- and, just for CYA, drill two additional holes: one near each
end of the ground-off area and add two more vertical bolts, hoping they
will compensate for the loss in torsional rigidity lost by grinding
off that section of lip on each side.
Does anybody see any red flags here mechanically? I
How about corrosion prevention? I've got to put *something*
bare metal left by the grinding.... and the overall rust-resistance on
these things looks pretty dismal.
Maybe that stuff they spray on auto underbodies... or the goop they use
for spray-in bed liners?