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Interesting write-up.
One question though...why did you reinstall the headliner before drilling the holes? It sounds like you used the 2x4 only so that you didn't drill through the headliner (vs drilling too far into the metal...I have no idea if this is a reasonable concern, btw), which could have been avoided by not reinstalling the headliner until everything was done, plus you could crawl back inside and see where the holes really ended up on the inside of the roof.
I gotta respect the effort though, I took the easy ($$) way out and bought a Yakima rack that attaches to the inside of the doors.
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-Wallace
'91 4Runner | 3.0 | 5sp | 4WD | 33x10.5r15 BFG AT | 15X8 Cragar black steelies | BJ spacers | OME 901 coils | OME shocks | OME steering stabilizer | Sonoran Steel Rear IFS Truss | ISR mod
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