OEM Roof Rack Add-Ons & T-Slot Cross Bars

[mblur05]

Did anything come of this? I’d be interested in option A. I’m also trying to figure out how to reinforce the front plastic supports, that tie in the beam to the A pillar. I think that’s a weak spot. I’ve been toying with the idea of filling in the plastic webbing with an epoxy, so strengthen it. I’ve also thought about epoxying that piece into the rail to bond it all together.

Well its funny that you mentioned it as just last week I redesigned option A bracket, version 2.0 with D shape openings. I've been busy with other things and doing other projects that this went on the shelf. I never did get a chance to 3d print test parts yet. Next week I will see about 3d printing a bracket for testing.

Still not sure whether to have them made from 1/4" aluminum or steel. Sendcutsend is who I used for my other brackets, are the ones that would make these for me. They cut, bend, and powder coat too.

When I'm back at work on Tuesday I will include a screen shot of v2.0 bracket. Let me know if you want just the top bracket alone or the top/bottom bracket option together.

Not sure anyone would tackle the oem plastic mounts to reinforce as steel or aluminum vs. Just getting a whole different rack system to replace the oem. Seems like a lot for such small change.

I was also thinking about making a version of the bottom plate that has a 90°bend going up on the outside part so you can mount other attachments maybe. Just not sure about slot holes or sizing yet.

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[Spicygb]

sure I’d love to see the version 2.0. I think the crossbars are definitely a weak point. Aluminum imo is better, simply for the fact of no rust.

 

[TrailRaider]

The plastic front mounts are definitely the weak point of the factory roof rack. There is more than a few pictures floating around to back that up. I had been tinkering with a window guard type frame tying the front mount locations to the mirror mounts in an effort to replace the plastic mounts. Recently I have decided to go without the roof full time and am in process of redesigning everything to mount my full size roof basket permanently mount to the roll cage. There are a few small advantages of living in So. Cal., No rain is one of them

 

[mblur05]

The plastic front mounts are definitely the weak point of the factory roof rack. There is more than a few pictures floating around to back that up. I had been tinkering with a window guard type frame tying the front mount locations to the mirror mounts in an effort to replace the plastic mounts. Recently I have decided to go without the roof full time and am in process of redesigning everything to mount my full size roof basket permanently mount to the roll cage. There are a few small advantages of living in So. Cal., No rain is one of them

Oh I agree those plastic front main windshield mounts should be aluminum or steel (do better ford or whoever made them). If I could get a 3d model of those mounts I might be able to redesign them and get them made in aluminum/steel and we could still use the plastic covers maybe. Great now I have to reverse engineer those like everything else!

However, like I noted before it would a lot of cost to do those parts too and at that point we might as well get aftermarket racks. The bronco life hardships we deal with am I right!

I'm in SoCal too, around the lax area.

 

[ChefBoris]

Good to know. I originally was trying to find oval shaped T-slot extrusions that could replace all of the OEM cross bars especially the rear one, however I couldn't really find anything to match it.

I haven't even looked at the rear cross bar section yet. Most likely I would need to engineer a mounting plate to fit the Rectangle Extrusion back there so it would match the height of the other cross bars. The plastic coverings would need to be trimmed if reusing them to fit the new cross bar shape. That is my idea for the rear section but its still a work in progress.

Yes, the main idea is to make it so you can add all those types of items, however not a rooftop tent.
I added a disclaimer about rooftop tent. Thanks for the input!

I am about to upgrade to trailrax so that I can get a Roam Arc270 . I don't want a roof tent . I want to carry a Thule box and an awning for my day and sometimes overnights to the mountains for skiing and mountain biking. I have an immediate need. Literally getting the invoice from a local dealer this weekend

 

[mblur05]

@Spicygb
This is the OEM Roof Rack Top Bracket Version 2.0. You can see I made D-Rings on both ends and I extended the 45deg slope. The D-rings have a thickness of .30" which should be thick enough for most stuff we strap down, if not I can always increase it. Plus if you include the bottom plate, that would make it even more stronger.

I'm still tweaking the bottom plate but I included a screenshot of both assembled so you can see what it should look like. I'm not sure if the bottom can be bent like I have it so that will need to be checked. The Bottom Plate idea was to help strengthen the top plate and everything else.

The Top Bracket mounting slot holes are adjustable within 3/8" either direction which mount to the factory rail cross bar threaded holes. I would consider drilling extra holes in the rails to add the same M6 Brass or SS threaded inserts so we can have more locations to mount the cross bars or just to add more cross bars. That is also part of my idea behind making these brackets.

The bracket will hold one T-slot 2inch wide 1020 Extrusion as the Cross Bar. This will replace the oval cross bars we have. Like shown below. The estimated length of these should be around 37.50" long since the brackets are 1/4" thick, and the rails are about 38" between them. But this will need to be tested before confirming the final length.

As for Side mounted options, I was thinking of creating another brace like others have done that would mount to the angled top bracket like shown, so you can add side mount stuff.

*Instead of the 15 series, I was thinking of changing to these 1020 extrusions which I believe all other racks are made with.

Side Mount Brace Idea I was thinking about:

 

[mblur05]

Here is Version 3.0 that I came up with as it adds Mounting Tabs on the side. This idea came to me in case you wanted added strength to add another mounting plate for an Awning or other things. I made a quick 3D sketch model of what it could look like on the top plate shown in pic #2.

I don't know if the bottom plate would be needed, especially since the top plate is 1/4" thick and it sits on the top of the main side rails. The top plates are only held by the (2x) oem M6 bolt locations where the oem crossbars mount to on the side rails.

Pic #3 shows a full assembly with all plates and cross bars and a 15 series extrusion. The Tabs do clear the outside plate section where you could mount a 1"x1" 1010 or the bigger 1.5x1.5 15series type Square Extrusion bar if you want to connect to the brackets like the assembly shown.

Let me know what you think of this version vs. V2.0!


*Pic #1 -Top plate and bottom plate shown

*Pic #2 -Shown with possible side mount plate idea

*Pic #3 -Full Assembly layout

 

[ChefBoris]

I am about to upgrade to trailrax so that I can get a Roam Arc270 . I don't want a roof tent . I want to carry a Thule box and an awning for my day and sometimes overnights to the mountains for skiing and mountain biking. I have an immediate need. Literally getting the invoice from a local dealer this weekend

Hey - I have the same upgrade. How'd it go. I'm looking at the Arc 270 materials and confused how it's going to attach to my Trailrax mod 90 and 270 mount.

 

[coastalbronco]

Hey @mblur05 , really cool idea- is this available? Is there more info on what’s needed from the factory rack to compliment the t slot cross bars and better front Mount?

 

[mblur05]

Hey @mblur05 , really cool idea- is this available? Is there more info on what’s needed from the factory rack to compliment the t slot cross bars and better front Mount?

Unfortunately, I haven't done anything with this. I was hoping it would generate some interest so that I would make them but that didn't happen as the OEM rack is very limited, so I forgot about it. The issue would be the rear factory Cross bar and how its mounted. I would have to re-engineer how the T-slot Extrusion could mount there in order to replace all the cross bars with T-Slot Extrusions to make it worth while.

 

[coastalbronco]

It seemed like there was some interest… I’m in though if you change your mind. There’s definitely a need for a slicker t slot integration

 

[mblur05]

It seemed like there was some interest… I’m in though if you change your mind. There’s definitely a need for a slicker t slot integration

I was thinking, maybe just forget the rear crossbar and leave it there or remove it. Then drill new mounting holes to the side rails with threaded inserts to add the Tslot extension cross bar just a few inches in front of the rear oem cross bar. I'm sure most items if they stuck out beyond should clear the oem rear bar if not removed. Just gotta coverup the plastic oem mounting parts if removed because there would be an oval opening there. lol

 

[coastalbronco]

So TBH, I don't have any roof rack setup yet - I just have bike, ski, etc racks that mount more securely to a t-slot crossbar (rather than using their hardware to clamp it to a crossbar)... and there doesn't appear to be anything! If I went with the OE, given the price, I'd be reluctant to start drilling and modifying it... which is why I was interested in your ideas. Then I was starting to wonder if I did modify the OE one - would it even be worth it to buy the full kit or just the side rails and feet?

 

[mblur05]

So TBH, I don't have any roof rack setup yet - I just have bike, ski, etc racks that mount more securely to a t-slot crossbar (rather than using their hardware to clamp it to a crossbar)... and there doesn't appear to be anything! If I went with the OE, given the price, I'd be reluctant to start drilling and modifying it... which is why I was interested in your ideas. Then I was starting to wonder if I did modify the OE one - would it even be worth it to buy the full kit or just the side rails and feet?

Well drilling holes on the side rails means you can have more mounting locations for the Cross bars. Unlike some other car companies that had OEM racks with channels on the side rails where you could slide the cross bars to different mounting positions all day long. The Bronco OEM rack has 3 positions for the cross bars: the rear that is fixed mounted in place, the middle location as it comes from the factory, and the 3rd place is up front above the drivers head. The only issue is the rear cross bar and how to mount a different shaped cross bar across and the fab work needed to get it to bolt to those side mounts. Not to mention the plastic covers would need trimmed to fit a rectangle extrustion instead the oval shape.

I would say if you don't have the OEM rack, maybe save yourself the headache and get an aftermarket one. I really wish Ford had one of those companies make the rack instead of whoever did this one.

As for the T slot Extrusions for the Cross bars, I have yet to find any "oval shaped OEM looking" Cross Bars with a T-Slot in them that could fit the factory mounting parts on the OEM rack. That's what I was originally hoping to find, but I've not seen anything other than brands like Thule or Yakima or some other brands that have Aero-Cross Bars with a T-Slot in the extrusion where the bars mount above the side rails on the OEM rack. It's such a simple thing Ford could change adding Aero bars that have T-slots in them fitting into the same oem mounts, they would sell out even if they were sold as accessories. They could easily make that happen.

 

[coastalbronco]

Interesting… appreciate all the information. And agree with you that there should be OE options that are more flexible and better at accommodating how people will use them

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