Since I drive about 2500 miles a month I'm always looking for ways to help the gas mileage on my 4runner. One of the ways that was mentioned on this board was to pull the stock roof rack off. I figured I'd have to leave the lengthwise pieces because of the ugly holes it'd leave but at least I could get rid of the crossmembers which is probably the cause of the most wind resistance.

Anyway, I had to unscrew the whole thing to get the crossmembers off and when I did, sure enough, there was RUST on 6 of the 8 holes! I'm meticulous about rust on the frame and underbody so this was a big surprise.

I sanded down the holes and surrounding paint and then sprayed it down with rustoleum severe rust treatment (something like that). Hopefully it won't rain until it's dry enough to put the lengthwise pieces back on. If anyone else does this I created a template with a diamond (1"x1" roughly) cutout in it to prevent sprayover of the rest of the truck. Of course, the freaking paint can nozzle still dripped onto the paint but I quickly wiped that up with a damp rag.

I figure on using RTV on the holes when I replace the screws to prevent anymore water from getting to it.

 

Your driving 2500 a month, wow. time for a small fuel efficient car.

 

I did consider that but...

Given the depreciation of even a cheap $3000 car, the maintenance costs, and the cost to insure it, I'd have to drive it a lot more than I'd be able to even if I got a third car which would crowd our already crowded tiny driveway.

That won't make sense unless I tell you that I hunt every chance I get and even when I'm not hunting, I often leave work during lunch breaks so that I can go and scout for new areas to hunt. A fuel efficient car would probably reduce the miles on the 4runner to 2000 a month instead of 2500 during hunting season.

Currently I just suck it up and deal with it. We'll have to move in another year or so and then I hope to make some major changes as to how much daily driving the 4runner will be doing.