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  #1  
Old 04-07-2013, 05:16 PM
annguyen1981 annguyen1981 is offline
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Default How To: Expo Roof Rack Installation

Since there was a lack of a how to for the expo roof rack, here's one.


Items needed:
Drill & drill bit
Hack saw to cut rails
Screwdriver or nut driver depending on what machine screws you purchase at the hardware store.
Threaded insert tool (Harbor Freight)
Silicone adhesive

You'll need to obtain a roof rack from a Ford Explorer. I got mine from the junk yard for $25. I also purchased the threaded insert tool kit from Harbor Freight for $16.

45 Piece Threaded Insert Riveter Kit


From the kit purchased at Harbor Freight, you will have to select the threaded insert you want to use. I selected the 10-24 pieces to do the job since I didn't want the holes to be too big. I brought one with me to the hardware store to purchase the correct stainless machine screws. Make sure you don't go too long. I also brought along the extra piece of rail left over from step 2 to ensure that the screw heads would not be too big or too small. Too small would mean they would fall right through the holes of the rack. Too big would mean the adjustable cross rails would not be able to be moved over the screw heads.

Step 1:
Remove the end cap from both roof rack rails.





Step 2:
Measure and cut to the desired length. I measured from the front end cap 36" since I've got an extended cab Ranger.





Step 3:
The end caps have a little notch that will prohibit it from going back on the cut rail. I took a wood chisel and removed the tab.

BEFORE:


AFTER:




Step 4:
Under each rail is a plastic piece that sits between the rail and the roof. You'll notice that the ends of the plastic have notches to accept the end caps. Since cutting the rail is needed, the notches need to be cut as well, otherwise the end caps won't fit properly. The plastic on the left has the original notch. The right side is after cutting, but before you notch it. I used some snips to get the job done.




Step 5:
Assemble the roof rack and crossmembers. I spaced the crossmembers at the very ends in order to ensure the assembly was square. (No picture available)



Step 6:
Measure and place the assembled rack on the truck. Getting the assembly centered from left to right was difficult since I had no one to help me. It took about 1/2 hour of going from side to side and adjusting little by little. (No picture available)



Step 7:
Using self-tapping screws, screw down the rack into the roof using the remaining 6 holes in the rail. This is only to mark the holes for drilling.




Step 8:
Remove the screws and assembly. Using the correct drill bit, enlarge all 6 holes to accept the threaded insert.




Step 9:
Apply silicone around the drilled hole, then apply the threaded insert.

SILICONE:


THREADED INSERT:




Step 10:
Once all 6 threaded inserts are done, apply the same silicone INSIDE the threaded insert. Reattach the rack to the roof with the screws purchased at the hardware store.

Step 11:
Stand back, take pictures, share said pictures, and have a beer if you drink. If you don't drink (like me), then continue sneezing up a storm because of your damn allergies acting up. Don't forget to wipe the snot off the roof as well.




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2003 Ranger Edge Stepside
| Sonic Blue | 4x4 | 4.0L V6 |

Mods when I bought her on 5.1.09
| Toneau cover | Dual exhaust |


Last edited by annguyen1981; 04-07-2013 at 05:20 PM. Reason: Fixed pictures
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  #2  
Old 04-07-2013, 05:20 PM
reconjb reconjb is offline
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Default Re: How To: Expo Roof Rack Installation

Sounds good but is it just me or are the pics not working

there they go
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Truck: 2000 Ford Ranger XLT 4.0 4x4 ext cab
My Build Thread
Mod Ideas
Don't Forget to:
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Mods: Brush guard|Front Hitch|Expo Roof Rack|Train Horn|Door/Dash/step/Hood Leds|2" lift|Rear Tow Points|On-Board Air System| 22" & 40" LED bar|and More!

Last edited by reconjb; 04-07-2013 at 05:22 PM.
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  #3  
Old 04-07-2013, 05:24 PM
Greasemonkey51 Greasemonkey51 is offline
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Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by reconjb View Post
Sounds good but is it just me or are the pics not working

there they go
I had to refresh then they worked nice write up tho..
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  #4  
Old 04-07-2013, 08:25 PM
WorkInProcess WorkInProcess is offline
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Default Re: How To: Expo Roof Rack Installation

Nice! I've been waiting for the write-up!

I just had one question. I'd like to use my roof rack for lights and maybe even a basket. In the basket I would put my spare, a hi-lift, and a 5 gallon fuel jug at most. Do you think the threaded inserts are enough to keep that much weight in place? Or would that be too much weight for the roof and/or roof rack attached by threaded inserts. I know other people have drilled through their roof and that would seem more durable for more weight.

Suggestions and thoughts?
__________________
2001 Ford Ranger Edge mostly stock, modifications include:
1 inch lift? big all terrain tires, stock rims
plastic mat liner inside
AVS wind deflectors
Sony subwoofer that is too big and a child's seat
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  #5  
Old 04-07-2013, 08:40 PM
CODYCODE CODYCODE is offline
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Thumbs up Re: How To: Expo Roof Rack Installation

Nice write up
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  #6  
Old 04-07-2013, 09:05 PM
Justincredible Justincredible is offline
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Default Re: How To: Expo Roof Rack Installation

best mod, works great love mine
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  #7  
Old 04-08-2013, 04:09 PM
annguyen1981 annguyen1981 is offline
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Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by WorkInProcess View Post
Nice! I've been waiting for the write-up!

I just had one question. I'd like to use my roof rack for lights and maybe even a basket. In the basket I would put my spare, a hi-lift, and a 5 gallon fuel jug at most. Do you think the threaded inserts are enough to keep that much weight in place? Or would that be too much weight for the roof and/or roof rack attached by threaded inserts. I know other people have drilled through their roof and that would seem more durable for more weight.

Suggestions and thoughts?
The reason why I used the threaded inserts was for added strength. When I was screwing in the self-tapping screws, I could still pull the rack off with minimal effort. I believe the inserts add better stability to the whole install.

The BEST option would be to use washers with nuts and bolts, but due to the double roof design of the Ranger, it would not be easily doable.
__________________


2003 Ranger Edge Stepside
| Sonic Blue | 4x4 | 4.0L V6 |

Mods when I bought her on 5.1.09
| Toneau cover | Dual exhaust |

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  #8  
Old 04-08-2013, 04:42 PM
reconjb reconjb is offline
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Posts: 10,687
Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by WorkInProcess View Post
Nice! I've been waiting for the write-up!

I just had one question. I'd like to use my roof rack for lights and maybe even a basket. In the basket I would put my spare, a hi-lift, and a 5 gallon fuel jug at most. Do you think the threaded inserts are enough to keep that much weight in place? Or would that be too much weight for the roof and/or roof rack attached by threaded inserts. I know other people have drilled through their roof and that would seem more durable for more weight.

Suggestions and thoughts?
I dont think the roof would be strong enough to hold that much weight
thats probably close to a hundred pounds im 110# and im not climbing up there
__________________
Truck: 2000 Ford Ranger XLT 4.0 4x4 ext cab
My Build Thread
Mod Ideas
Don't Forget to:
Create a Signature
Show your system

Mods: Brush guard|Front Hitch|Expo Roof Rack|Train Horn|Door/Dash/step/Hood Leds|2" lift|Rear Tow Points|On-Board Air System| 22" & 40" LED bar|and More!
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  #9  
Old 04-08-2013, 10:56 PM
WorkInProcess WorkInProcess is offline
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Posts: 57
Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by reconjb View Post
I dont think the roof would be strong enough to hold that much weight
thats probably close to a hundred pounds im 110# and im not climbing up there
Good point. Roof racks still look pretty with lights. A bit naked though.
__________________
2001 Ford Ranger Edge mostly stock, modifications include:
1 inch lift? big all terrain tires, stock rims
plastic mat liner inside
AVS wind deflectors
Sony subwoofer that is too big and a child's seat
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  #10  
Old 04-09-2013, 09:35 PM
Retroboy1989 Retroboy1989 is offline
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Join Date: Nov 2011
Posts: 1,078
Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by annguyen1981 View Post
The reason why I used the threaded inserts was for added strength. When I was screwing in the self-tapping screws, I could still pull the rack off with minimal effort. I believe the inserts add better stability to the whole install.

The BEST option would be to use washers with nuts and bolts, but due to the double roof design of the Ranger, it would not be easily doable.
Are do all rangers have a double roof?
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  #11  
Old 04-10-2013, 06:06 AM
reconjb reconjb is offline
Found a Diesel
 
Join Date: Aug 2010
Posts: 10,687
Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by WorkInProcess View Post
Good point. Roof racks still look pretty with lights. A bit naked though.
id like to do a basket then put lights on it then you can carry some light stuff up there
__________________
Truck: 2000 Ford Ranger XLT 4.0 4x4 ext cab
My Build Thread
Mod Ideas
Don't Forget to:
Create a Signature
Show your system

Mods: Brush guard|Front Hitch|Expo Roof Rack|Train Horn|Door/Dash/step/Hood Leds|2" lift|Rear Tow Points|On-Board Air System| 22" & 40" LED bar|and More!
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  #12  
Old 04-10-2013, 06:52 AM
Bob C. of Indiana Bob C. of Indiana is offline
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Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by reconjb View Post
id like to do a basket then put lights on it then you can carry some light stuff up there
Like a 42 piece camping kit? A blanket and 41 condoms...LOL
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  #13  
Old 04-10-2013, 06:53 AM
ford4thot ford4thot is offline
2019 SSVT Ford 'Maro
 
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Posts: 14,258
Default How To: Expo Roof Rack Installation

Quote:
Originally Posted by Bob C. of Indiana View Post
Like a 42 piece camping kit? A blanket and 41 condoms...LOL
Lol! Hey bob check out the videos posted in the BS/Watercooler thread:-)
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  #14  
Old 04-10-2013, 06:59 AM
Bob C. of Indiana Bob C. of Indiana is offline
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Default Re: How To: Expo Roof Rack Installation

Quote:
Originally Posted by ford4thot View Post
Lol! Hey bob check out the videos posted in the BS/Watercooler thread:-)
What page? I have never looked at the watercolor thread...
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  #15  
Old 04-10-2013, 07:00 AM
ford4thot ford4thot is offline
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Default How To: Expo Roof Rack Installation

Quote:
Originally Posted by Bob C. of Indiana View Post
What page? I have never looked at the watercolor thread...
FRF Watercooler / BS Thread XV
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