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Discussion Starter #1 (Edited)
The rack arrived on Saturday, far earlier than expected! I could hardly wait, so I enlisted a good friend to help me assemble it on Sunday. My dog made sure to help by sticking his giant head in for some ear scratching whenever it looked like we were working too hard. I took a few pictures of the build, but not enough to give you an idea of the entire build process. The build took all day and we stayed busy.

All the materials were securely packed and there was no damage. The kit included printed instructions, which I found fairly easy to follow. The construction itself I found to be minimally complicated, but fairly labor intensive. This was most particular when it came time to attach the cross bars, with the numerous nuts and bolts securing each one. The parts kit is primarily comprised of 1/4" bolts and 5/16" bolts with lock-nuts. I torqued all the 1/4" bolts to 100 in/lbs and the 5/16 to 150 in/lbs. I was particularly grateful to have my friend's help as all the nuts/bolts add up to a lot of labor. Typically, one of us would hand tighten bolts in place and the other would follow up with a torque wrench.

Mounting the rack itself on the vehicle gave us a pretty good headache due to the relationship between the roof attachment feet, the threaded clips which accommodate the rack mounting bolts and the rack itself. The clips attach to the feet and provide the threaded opening to run a bolt through thus securing the rack to the feet. The clips float a bit and have to align with openings in the feet and rack itself. That part was practically a nightmare. I'll be curious to see other's more definitive posts and how they got the clips to work in a smoother way. We struggled with it and still have some adjustments to make.

The kit itself appears to be well made. The powder coating appears to be very thick and the overall weight of the rack is not bad, maybe 60 pounds. It came with a nice rubberized gasket which mounts underneath the front fairing to cut wind noise. The assembled rack appears solid and I find stunning to look at. I drove on the freeway after work and noticed some marginal increase in wind noise at 65 mph, but the wind was also blowing quite hard. There was no whistling or vibrations at all that I noticed.

It would have been far easier to mount another type of rack with simpler construction and fewer parts, but I think this one is perfect for what I was looking for...a balance between form and function. This summer I will be looking into ways I can mount some flood lights to the sides and in back.

Regards,

Desmo
 

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Thanks Desmopilot for the feedback and write up!

It's great to get external feedback so we can look into potential changes that may make it easier for future customers. We're glad your happy with the product! We're eager to wrap up the design of the RTT-specific load bars that we hope to push to market here in the next month or so. More to come soon on that!

Cheers
 

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Thanks Desmopilot for the feedback and write up!

It's great to get external feedback so we can look into potential changes that may make it easier for future customers. We're glad your happy with the product! We're eager to wrap up the design of the RTT-specific load bars that we hope to push to market here in the next month or so. More to come soon on that!

Cheers
Staying tuned for those RTT load bar solutions :)
 

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Thanks Desmopilot for the feedback and write up!

It's great to get external feedback so we can look into potential changes that may make it easier for future customers. We're glad your happy with the product! We're eager to wrap up the design of the RTT-specific load bars that we hope to push to market here in the next month or so. More to come soon on that!

Cheers
When will compatible accessories be available, like gas cans mounts, axe/shovel mounts, self-recovery board mounts, etc?

Love this roof rack.
 

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When will compatible accessories be available, like gas cans mounts, axe/shovel mounts, self-recovery board mounts, etc?

Love this roof rack.
We are working on tweaking our new tool mounts that are available for our bed rack system for use on our roof racks which we hope to release very soon (no eta just yet). I've attached a photo of the tool mounts below.

The rail system on the rack is fairly universal and should accept some of the accessories offered by companies such as Front Runner Outfitters, although we haven't had the time to fully test each configuration out there.

The roof rack is still a brand new product for us and as we head into the new year, we'll have more mounting options going forward. In the mean time we've seen people get pretty creative with their own custom mounting solutions. :smile
 

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Discussion Starter #12
Thanks! My friend and I spent about 8 hours prepping, assembling, mounting and adjusting the rack. A couple of the mounts didn't line up correctly, so that cost us some time. Having a 2nd person helped with organizing, visualizing the assembly, installing the hundred plus nuts and bolts. Lastly, I needed someone to help me lift the rack up on the rig and help with alignment. Since it's comprised of so many pieces, the mounting process involves a series of adjustments to align the feet, clips and rack placement.

Long story short, I never would have finished it in one day if I was by myself. Actually going to be working on it again this weekend to try and get the mounting bolts to line up better.
 

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Discussion Starter #13
Build update: At the time of the original assembly, I wasn't able to get several of the bolts installed which secured the rack to the mounting feet. I think I had 8 of the 12 bolts installed. The center foot on the passenger side just needed to be shifted forward by an 1/8 inch or so, but the drivers rear foot seemed to extend out too far to sync up with the holes in the rack. I'm probably not explaining this very well...

Anyway, I removed all the rack mounting bolts and suspended the rack above the FJ with ropes tied to the garage rafters. Thought it would simplify aligning things. A buddy came over to lend me a second set of eyes on the issue of making the rear bolts fit. We determined that if we extended the upper bolt slots (the ones that meet the rack, not the ones that mount to the roof) on each rear foot all the way inboard, it would give us enough room to match up the bolt holes and the threaded clips. We clamped the feet to my work bench and drilled out about 1/8 inch of metal, thus lengthening the bolt channel inwards as far as we could. I then remounted the feet, torqued them down and installed the threaded clips. Next, we aligned the rack and lowered it down from the ropes. Every mounting hole and clip aligned perfectly.

I had a celebratory beer before I wrote this, so hopefully it makes sense. I think mounting the rack to the FJ could be simplified if all the mounting slots on the feet were extended some. She's on now and it looks perfect. I love it and hopefully I won't be taking it apart again for a very long time if ever. :rocker:
 

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Build update: At the time of the original assembly, I wasn't able to get several of the bolts installed which secured the rack to the mounting feet. I think I had 8 of the 12 bolts installed. The center foot on the passenger side just needed to be shifted forward by an 1/8 inch or so, but the drivers rear foot seemed to extend out too far to sync up with the holes in the rack. I'm probably not explaining this very well...

Anyway, I removed all the rack mounting bolts and suspended the rack above the FJ with ropes tied to the garage rafters. Thought it would simplify aligning things. A buddy came over to lend me a second set of eyes on the issue of making the rear bolts fit. We determined that if we extended the upper bolt slots (the ones that meet the rack, not the ones that mount to the roof) on each rear foot all the way inboard, it would give us enough room to match up the bolt holes and the threaded clips. We clamped the feet to my work bench and drilled out about 1/8 inch of metal, thus lengthening the bolt channel inwards as far as we could. I then remounted the feet, torqued them down and installed the threaded clips. Next, we aligned the rack and lowered it down from the ropes. Every mounting hole and clip aligned perfectly.

I had a celebratory beer before I wrote this, so hopefully it makes sense. I think mounting the rack to the FJ could be simplified if all the mounting slots on the feet were extended some. She's on now and it looks perfect. I love it and hopefully I won't be taking it apart again for a very long time if ever. :rocker:
A little late on the response with the holidays but we appreciate the feedback on the mounting feet. I'll pass this info along! Glad everything else went smoothly :cheers:
 

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Discussion Starter #15
Thanks for making such an excellent product!

I forgot to add in my build info that I used generous amounts of 100% clear silicon in and around the mounting holes in the roof. I didn't want any water seeping past the brackets and into the cab. Seems to be working great so far in our wet winter.
 

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Desmopilot - I received my ExpOne rack the other day. In the instructions, they have the rear mounting feet in different positions ( see page 9 vs. 12 ) What position did you put the rear mounting brackets in yours? Also, did you use a spacer in the rear? thanks!
 

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Discussion Starter #17
Desmopilot - I received my ExpOne rack the other day. In the instructions, they have the rear mounting feet in different positions ( see page 9 vs. 12 ) What position did you put the rear mounting brackets in yours? Also, did you use a spacer in the rear? thanks!
I just saw this, sorry! I will check tonight and get you some info and maybe pics.
 

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Discussion Starter #18
Desmopilot - I received my ExpOne rack the other day. In the instructions, they have the rear mounting feet in different positions ( see page 9 vs. 12 ) What position did you put the rear mounting brackets in yours? Also, did you use a spacer in the rear? thanks!
OK, I checked my install and the rear feet are definitely installed as shown on page 12 Fig 2A, bottom mount facing inboard and upper mount facing out. Also, it looks like I used spacers under all of the mounts for front, middle and rear. If I recall, I used the thicker ones for front and middle and the thinner ones for the rear. I think there were thinner ones anyway. It made the rack follow the lines of the roof more accurately and I liked having that solid flat surface to rest all the mounting feet to...at least that's my recollection. Hopes this helps!
 

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Nice!
OK, I checked my install and the rear feet are definitely installed as shown on page 12 Fig 2A, bottom mount facing inboard and upper mount facing out. Also, it looks like I used spacers under all of the mounts for front, middle and rear. If I recall, I used the thicker ones for front and middle and the thinner ones for the rear. I think there were thinner ones anyway. It made the rack follow the lines of the roof more accurately and I liked having that solid flat surface to rest all the mounting feet to...at least that's my recollection. Hopes this helps!
Thank you for the reply!
 
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