To read the original full thread and post questions/comments on this topic, please go to Roof rack crossbar mod: 3 is stronger than 1 (pics)
It's not that the OEM roof rack crossbars are
completely worthless. They just have difficulty supporting too much weight when they're separated from each other.
Seeing some posts where jerry cans were mounted atop of one or two crossbars, I figured that combining three of them side-by-side would provide an ample support system. And, it certainly does!!
The only problem is, there's not quite enough room at the back of the rack to put three in a row between the two rear vertical pillars, so some slight modification to one of the crossbars will have to be done.
Since a couple of the crossbars are slightly different in length, pick two that go together perfectly, and pick a third that fits across the top tier just ahead of the support pillar. The remaining cross bar will have to be shortened (cut), and in doing so, you'll have to use two self-tapping screws to replace the original torx head screws.
That particular crossbar will have to be notched to fit behind the support pillar. (Be sure to notch it on the forward side as indicated by the arrow on the mount.)
Once mounted, you’ve got yourself a VERY strong cargo area that even supported the weight of this 245-pounder sitting on it. (Sorry, I couldn’t take a picture of myself at the same time.) So, a couple of full jerry cans (or more) shouldn’t have any problem at all. (Obviously, provisions for tie-down straps will have to be added for securing the jerry cans.)
