Customer Spotlight: A Custom 80/20 Roof Rack Build

Steven BornJul 17, 2025

The Inspiration

One of our customers, a 2023 Tacoma Off Road owner with a short box and a Leer canopy fitted with Thule tracks, came to us looking for a versatile roof rack solution. He needed something that could handle heavy loads like lumber for home projects, outdoor gear, and even a canoe or kayak. Strong yet lightweight, the 80/20 t-slot system turned out to be the perfect fit for his needs, thanks to its modularity and robustness.

Design and Planning

Before starting the build, he booked a consultation with our staff at RMMC in our showroom in Abbotsford to go over our options an learn how it goes together.

He then took precise measurements of the track on his canopy, a crucial step to ensure a snug fit and optimal functionality. Armed with those measurements, he explored the 80/20 catalogue to select the right components for the job.

Component Selection

After careful consideration, he chose the following 80/20 components:

1515-LITE-BLACK - 1.5” X 1.5” Lite T-Slotted Profile - Four Open T-Slo | Rocky Mountain Motion Control : This profile provides the necessary strength for medium loads without adding excessive weight.
4336-BLACK - 15 Series 4 Hole - Tall Gusseted Inside Corner Bracket | Rocky Mountain Motion Control: These brackets are perfect for connecting larger ratchet straps, ensuring secure tie-down points.
4302-BLACK - 15 Series 2 Hole - Inside Corner Bracket | Rocky Mountain Motion Control: These are used at the ends of the roof rack bars to keep materials in place when loading and unloading.
3675 - 1/4-20 Slide-In Economy Stainless T-Nut - Centered Thread | Rocky Mountain Motion Control: Used for connecting the roof rack to the Thule tracks on the Leer canopy.
3678 - 5/16-18 Slide-in Economy SS T-Nut - Offset Thread | Rocky Mountain Motion Control: Used to connect gussets to the post and cross bar
3611 - 5/16-18 x .625" Button Head Socket Cap Screw | Rocky Mountain Motion Control and 3663 - 1/4-20 x .625" Button Head Socket Cap Screw (BHSCS) | Rocky Mountain Motion Control: Stainless hardware prevent rust and ensure long-lasting durability.
2110 - Standard T-Slot Cover | Rocky Mountain Motion Control: To reduce wind resistance and provide a surface to slide material on top of the cross bars
2030 - 15 Series End Cap with Push-In Fastener | Rocky Mountain Motion Control: To finish off the ends of the profile as each end gets exposed after cutting

Building the Roof Rack

Cutting the Profiles

He let us know the sizes of the bars he needed cut and completed and picked up after notifying it was ready. These were cut from some stock sizes of 1515-LITE-BLACK profiles we had on hand, forming the main structure of the rack.

Assembling the Frame

He connected the main profiles using the 4336-BLACK gusset brackets, which gave the frame the rigidity needed to handle substantial loads.

Adding the End Brackets

At the ends of the roof rack bars, he attached the 4302-BLACK L brackets, essential for keeping materials in place, especially when sliding items onto the rack.

Tapping and Securing the Ends

The ends of each profile were tapped to securely fit the end caps, resulting in a clean, finished look with added structural security.

Custom Angles and Fasteners

He cut the support bars at a slight 5-degree angle to follow the contour of the canopy, and opted for all stainless-steel fasteners to resist rust. Light-duty blue Loctite was applied throughout to keep everything secure against vibration during off-road use.

Adding T-Slot Covers

To make sliding cargo easier and to eliminate wind noise, he added t-slot covers, measuring and cutting them with scissors for a perfect fit. A simple addition that made a big difference in day-to-day usability.

Assembly Tools and Techniques

For assembly, he used 3/16 and 5/32 ball end hex wrenches, particularly handy for tight spaces and working at awkward angles. To mount the rack to the truck, he used 10 Series 1/4-20 t-nuts (PN 3678) with 5/8" long bolts, dropping everything into place so the gussets were centered and the t-nut could securely engage the Leer canopy track.

Benefits of the Modular Design

What he appreciates most about the 80/20 system is its modularity. Down the road, he can add more bars for a full basket design, reconfigure the setup for an awning, or expand storage as his needs change, all without starting from scratch.

Conclusion

Building a roof rack with the 80/20 t-slot system offers unmatched customization and strength. It’s a perfect project for DIY enthusiasts who need a versatile solution for their hauling needs. The modular nature of the system means you can adapt and expand your design as your requirements evolve.