ROOF RACK GAS CAN MOD: Instructions w/ pics

[LandCruiserSteve]

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.)

[LandCruiserSteve]

therelaxer previously said:

How much did you cut off and what did you use to cut the crossbar?

Just under a half inch. Used a hack saw.

You'll know it's just right when you can see the first OEM screw hole peeking halfway through the slide groove. (The second OEM hole was used for one of my self-tapping screws. The third hole in, I drilled.)

[LandCruiserSteve]

Final touches:

I added the eye-bolts to the center crossbar spaced at exactly 9 5/8" from one another (starting at the edges of the crossbar mount). Be careful when tightening the eyebolts. Tighten just enough to collapse the lock washer. Beyond that will start collapsing the crossbar itself.





The spacing was based upon the width of the Blitz plastic gas cans with the self-venting cap.




The spacing worked out to accomadate three of the Blitz gas cans. (Sorry, I didn't have a third one for the photo op.) Two cans can be individually ratchet-strapped . . . . or if three cans are used, a single rachet-strap can go through all three handles.





To test the integrity of this gas can rack mount set-up, I filled each can to capacity and drove the FJ to and from work. No shifting, no crossbar sagging, no spilling and no wind noise.

Short of upgrading to a heavy-duty aftermarket rack, this does the perfect job of supporting and carrying that additional 15+ gallons of spare gas.