DIY Roof rack cross beams

So we have a honda pilot - that we just got back from the autobody shop after a run in with an out of bounds box truck - and while big it barely seats the 7 of us. It seats 8, so we have an empty seat but as the kids get bigger we find room more and more scarce. So when we planned a vacation with all of us we had to consider where we would put all of our junk.

Enter a Thule roof rack from craigslist I snagged for less than half price of retail. It requires crossbars to install- which we lacked until tonight.

Here is a parts list:

2x 1 inch wide by 4 feet wide steel square stock
4x 5/16 U bolts
8 - 5/16th acorn nuts/cap nuts
8 lock washers
3/8th inch vinyl tubing


Fit the bars across the top of the running bars, align the Ubolts and mark where you need to drill

drill holes and fit everything together.

I got the inspiration for this from an Instructables guide sheet, so the credit goes there: http://www.instructables.com/id/DIY-Roof-Rack-Ford-Freestyle/

We tested it out tonight with the roof rack on and there were no weird sounds or vibrations even at 80 miles an hour. I took off the empty Thule box and willow took it to a friends baby shower, she said there was a whooshing sound but nothing annoying - I think its the open ended tubing, something duct tape will fix.