So I'm just looking for some input on this. At some point I want to do a full-length roof rack and an RTT on my Ex but with the factory rail mounts being plastic I want to replace them with some beefier rails to support the weight. I don't want to pay a fabricator several hundred dollars to build rails for me so I'm thinking of using Unistrut. The plan is to have bolts running through the factory mounting holes in the roof, reinforced above the headliner with large washers and nuts. Then I'd just use more Unistrut for the crossbars. Of course the mounts would be sealed with RTV or something to keep water out. Seems like that'd be plenty strong but I've not seen it done. I've seen some Unistrut roof racks, I just haven't seen it used to actually mount a rack to the roof.
FWIW, I'm thinking about using an ATV ramp for the rack. Cheap, lightweight, low profile.
FWIW, I'm thinking about using an ATV ramp for the rack. Cheap, lightweight, low profile.
