Roof rack install instructions
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Senior User
Joined: Nov 2001
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From: Sacramento
Roof rack install instructions
'Any tips or warnings on installing a recycled Aerostar roof rack onto a previously unracked 96 extended Aerostar? I'm assuming it attaches with those rubber/metal expanding nut inserts?
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Joined: Mar 2001
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From: cincinnati hamilton
Roof rack install instructions
i also recycled a roof rack from a junk yard and installed it on my 91 aerostar. i took some time to clean and repaint the rack. then i measured an already installed one at a car lot for location, give or take an inch. i predrilled a pilot hole (very small)for each mounting hole and put a dab of silicon sealer in each hole. then i used a sheet metal screw with a flat head so the adjustable bars could slide over it. (or you could file the heads down a bit). i torqued them in till snug plus 3/4 turn. i have had no trouble with it. and have used it to hold a roof cargo carrier on summer vaca. your expanding nut idea sounds good, just check to see if the cross bars will slide over them,..may be a mute point though, as you can take them off and put them were you want anyway... a dab of silicone in the holes may help prevent leaks..just my two cents worth!!! 
rick
rick
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Senior User
Joined: Nov 2001
Posts: 319
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From: Sacramento
Roof rack install instructions
Thanks for your reply. I wouldn't have thought about the silicone sealer, good idea. I had a Jeep Cherokee that had a recycled rack installed by persons unknown. I found out that the rack and a sheet of plywood go airborne at 47 MPH, if not securely bolted on to the roof metal....Luckily, no one behind me at the time.
