Cross bars forever!!

WhIle I'm sure my TD's factory rack would be adequate for something lightweight - like a container of clothing - I wanted something I could use for hauling building materials.
Since he no longer owned any vehicles with roof-gutters, a friend gave me his pair of Thule gutter-mount racks. A couple of the legs had broken clamp-knobs, but I lucked-out by finding a sack-full of Thule legs at a yard-sale for $7.
I then fabricated some clamp-bars so I can use my Thule for hauling plywood.

Happy Motoring, Mark

__________________
DrDKW

Ive had plenty of plywood on the racks of the TD when I had one. Used 2x2 for cross bars.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

I've used both Thule and Yakima gutter mount racks on my TD. Carried hundreds of pounds of canoes up there in addition to tons of lumber. I wouldn't trust the factory rack to carry much more than 50 lbs or so.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Why not? The mounting place is pretty rigid. Not as rigid as the gutters perhaps but I am sure I have had 200lb on the TD racks before...

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Nice work Chad! That's definitely stronger than the bamboo crossbars I use for surfboards.

Does that wind deflector double as a snowboard? It looks like it has side-cut and perhaps some reverse camber for those big freshy powder days!

It's too bad Thule sticks it to you on the foot-price. I guess its because they know the other parts are readily available.

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1981 300TD "The Green Lantern"
1980 300TD
1983 300D Euro "China Cat"

I think Thule gutter mount racks are rated to a max of 150 lbs (not 100% sure). Anyone with a TD owners manual? rack capacity should be in there.

I have the Thule Mountaineer roof top box on a gutter mount rack with long crossbars and it's great! The box is so big it can carry 2 full size wheels. The only thing with the long bars is you hit your head if you're not careful.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Another reason for driving older cars with rain gutters- stronger roof racks.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

My W211 has the best solution, hard mounting points built into the car's roof. The correct Thule racks bold directly to the car, very secure.

I just read that the factory roof rails are rated for 80 kg. (173.4 lbs.).

The Thule rack system is only rated for 165 lbs.

__________________
Chad
2006 Nissan Pathfinder LE
1998 Acura 3.0 CL
OBK#44
"Pleasure in the job puts perfection in the work." - Aristotle (384-322 B.C.)

SOLD
1985 300TD - Red Dragon
1986 300SDL - Coda
1991 - 300TE
1995 - E320
1985 300CD - Gladys

Rack tidbit: The Yakima round bars are sized so that a piece of 1/2" galvanized pipe slips nicely inside. I've created extendable roof bars by buying four pieces of 18" 1/2" galvanized pipe, putting a cap on one end and sliding them into the roof bars. I then drill a hole through the Yakima bars at each end and in a variety of places on the 1/2" galvanized and put a hitch pin through the hole. I can slide out the galvanized to a variety of lengths based on the holes I drilled.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Is that rating for poundage placed on the rails directly on the roof or on the raised rails on either side?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Just the rails. I can't find the weight capacity of the roof when using the rails to contain the cargo.

__________________
Chad
2006 Nissan Pathfinder LE
1998 Acura 3.0 CL
OBK#44
"Pleasure in the job puts perfection in the work." - Aristotle (384-322 B.C.)

SOLD
1985 300TD - Red Dragon
1986 300SDL - Coda
1991 - 300TE
1995 - E320
1985 300CD - Gladys

Even if I wanted to load 3 - 4 sheets of plywood on my chrome factory rack, I still wouldn't trust any cords or straps to secure it safely.
I drilled holes near the ends of my Thule rack-bars just outside the gutter-mounts. The holes are exactlly 4-feet apart and are used to bolt a pair of clamp-bars made from 1" iron pipe to secure plywood.

Happy Motoring, Mark

__________________
DrDKW

To each their own. I have been bringing plywood home for years without issue with rope / saran wrap.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42