So found out that Mazda no longer stocks the $400 roof rack and Thule wants $600 for it...not only that, but it doesn't have adjustable cross bars. So here is an $85 solution. Easy build. (inspiration for the rubber stoppers came from a guy on youtube who tried something similar on his Mazda 5). This probably won't clear a sunroof unless you get more creative than me. Once everything is on, it's SOLID. Interlinking all 4 roof mounting points gives it serious rigidity.
4pc - 1.25" high #10 Solid Rubber Stoppers (2 packs of 3) - https://www.amazon.com/dp/ (commissions earned)
4pc - M6 x 50mm - Hand Fasteners (1 pack of 4) - https://www.amazon.com/dp/ (commissions earned)
4pc - SuperStrut End Caps (2 packs of 2) - SECB-B2-10
4pc - Superstrut 1" Pipe Clamps - "Z703 1-25"
8-10 Washers (fit M6 bolt)
10ft - 1" Conduit - Round
10ft - SuperStrut - "ZB1400HS 10"
Total cost is about $85. (if you source the stoppers cheaper (4 instead of 6), skip the end caps and use M6 bolts instead of hand fasteners, you could shave $20 off the price).
Tools Needed:
BFH (preferrably a sledge, 1" conduit is tougher than it looks)
Hack Saw for hacking metal.
Drill with drill bits.
Screw Driver
Tools not "required":
High speed grinder and wire wheel.
NOTE: It is CRITICAL that that stopper is AT LEAST 1.25" high! The Superstrut clamps need that much space. If not, you can try and shim between the conduit and stopper. Also, the M6 fasters will need shimming...they are a tad too long. The mounts in the roof only have 1cm worth of threads.
To build:
It's pretty straight forward.
1. Drill a hole in the center of 4 Rubber stoppers. Not so big that the M6 fasteners can fall out once inserted.
2. On one side of the car, mount 2 of the stoppers and the fasteners.
3. Measure from the outside tops of the stoppers.
4. Cut 2 pieces of Conduit that length. (now you have a third piece which makes for a great ratchet busting cheater bar)
5. Smash the ends of the conduit down flat with the BFH.
6. Put the conduit up to the stoppers on the car and mark where the bolts need to go. Be as precise as you can.
7. Drill holes in the flattened conduit ends.
8. Take the stoppers off the car. Put the conduit between the fastener and stopper and test fit it on the car.
9. Adjust/lengthen the holes in the conduit until it mounts correctly and easily.
10. Do the other side.
11. If you have a grinder, grind the ends of the conduit til they're rounded and smooth the edges with a wire wheel.
12. Use 2-3 washers between the M6 fastener and the stopper to take up the extra space so you can really tighten the conduit/stopper assembly down without the fasteners bottoming out.
13. Cut 2 Superstrut lengths 43" and 45" (or as long as you want for more overhang). The car is not the same width front to back...hence the 2 lengths.
14. Put the end caps on the Superstruts.
15. Mount the Superstruts wherever you want on the conduit with the clamps.
DONE!
This allowed me to put one of those black Craftsman blow molded plastic carriers on the roof. It has mounts about 22" apart. The picture shows the cross beams in the exact spot I need for it.
Once you have everything tightened and right where you want it...you can take the rack off in 1 piece! Just use the hand fasteners to release it from the roof. The Rubber Stoppers do not appear to leave any marks and protect the roof!
...and yes...
It howls just as much as you'd expect from an $85 DIY roof rack. Just turn your radio up.
Pics:
-Mike
4pc - 1.25" high #10 Solid Rubber Stoppers (2 packs of 3) - https://www.amazon.com/dp/ (commissions earned)
4pc - M6 x 50mm - Hand Fasteners (1 pack of 4) - https://www.amazon.com/dp/ (commissions earned)
4pc - SuperStrut End Caps (2 packs of 2) - SECB-B2-10
4pc - Superstrut 1" Pipe Clamps - "Z703 1-25"
8-10 Washers (fit M6 bolt)
10ft - 1" Conduit - Round
10ft - SuperStrut - "ZB1400HS 10"
Total cost is about $85. (if you source the stoppers cheaper (4 instead of 6), skip the end caps and use M6 bolts instead of hand fasteners, you could shave $20 off the price).
Tools Needed:
BFH (preferrably a sledge, 1" conduit is tougher than it looks)
Hack Saw for hacking metal.
Drill with drill bits.
Screw Driver
Tools not "required":
High speed grinder and wire wheel.
NOTE: It is CRITICAL that that stopper is AT LEAST 1.25" high! The Superstrut clamps need that much space. If not, you can try and shim between the conduit and stopper. Also, the M6 fasters will need shimming...they are a tad too long. The mounts in the roof only have 1cm worth of threads.
To build:
It's pretty straight forward.
1. Drill a hole in the center of 4 Rubber stoppers. Not so big that the M6 fasteners can fall out once inserted.
2. On one side of the car, mount 2 of the stoppers and the fasteners.
3. Measure from the outside tops of the stoppers.
4. Cut 2 pieces of Conduit that length. (now you have a third piece which makes for a great ratchet busting cheater bar)
5. Smash the ends of the conduit down flat with the BFH.
6. Put the conduit up to the stoppers on the car and mark where the bolts need to go. Be as precise as you can.
7. Drill holes in the flattened conduit ends.
8. Take the stoppers off the car. Put the conduit between the fastener and stopper and test fit it on the car.
9. Adjust/lengthen the holes in the conduit until it mounts correctly and easily.
10. Do the other side.
11. If you have a grinder, grind the ends of the conduit til they're rounded and smooth the edges with a wire wheel.
12. Use 2-3 washers between the M6 fastener and the stopper to take up the extra space so you can really tighten the conduit/stopper assembly down without the fasteners bottoming out.
13. Cut 2 Superstrut lengths 43" and 45" (or as long as you want for more overhang). The car is not the same width front to back...hence the 2 lengths.
14. Put the end caps on the Superstruts.
15. Mount the Superstruts wherever you want on the conduit with the clamps.
DONE!
This allowed me to put one of those black Craftsman blow molded plastic carriers on the roof. It has mounts about 22" apart. The picture shows the cross beams in the exact spot I need for it.
Once you have everything tightened and right where you want it...you can take the rack off in 1 piece! Just use the hand fasteners to release it from the roof. The Rubber Stoppers do not appear to leave any marks and protect the roof!
...and yes...
It howls just as much as you'd expect from an $85 DIY roof rack. Just turn your radio up.
Pics:
-Mike