This is a contractor's rack build, same concept would work great for a cargo rack. Threw it together over a few evenings for <$25 in fasteners using some 1/8" C channel which was pulled out of an old bed frame. Each of the four corners supports my 215#s without any give whatsoever.

Had been looking to retire my 1st gen from work duty and try out the new drill press, this was the chance.


Pulled the interior accessories and trim.


Some hidden screws to watch out for in the back corner. And a mouse's nest to fall in your face if you're lucky like I was.


Pulled headliner through the tailgate.


Seemed like a good spot for some plug welds.




Buffed up for primer, rubberization and paint.


Total fasteners used for the project -
4 - 3/8" grade 5 bolts (Fastenal didn't have fully threaded grade 8s)
12 - 3/8 nuts
16 - 3/8 lock washers
4 each flat washers - 3/8, 1/2 and 3/4


Kept holes as close to edge rail as possible while clearing the strengthening dimple in the crossmember. 3/8" bolt heads will sit inside the track, don't interfere with headliner reinstall.


Accept no subs. I frame and glaze commercial skylights for work, this is all we use, nothing else compares. Get yours at

$50 and works awesome! Deal of the year!


Minor kink in the steel when nuts were cinched supertight, because bolts were slightly skewed outwards with the curve in the frame where mounted, and steel was level. Doesn't affect performance.


Me and a 50# ladder bouncing on one side didn't budge it. Also tried just me bouncing on each corner individually.


Real stress test came next day - 125 miles to a job with 3 ladders strapped on. Rutted up dirt roads to 75mph on the freeways, insurance claim free! That's some bang for the buck.

 

Just to update this for others building and put it back on Google, I used this regularly for work for several years with no issues. Held 40' ladders and loads of lumber much more securely than factory aluminum racks and I recall feeling more confident in it than I did even on my other Rhino Rack setup. Body was starting to rust out, again, and then I was T boned by a drunk at low speed which pretty well finished off the 4Runner but rack was still going strong.