Postby smj999smj » Mon Dec 23, 2013 1:47 pm
Back in the "old days," when we used to install roof racks on some Pathfinders as a dealer option, the kit would come with nut-serts with a tool to install them. We would mark the location of the holes, put a piece of vacuum hose over the appropriate size drill bit (to prevent the bit from going to far and through the headliner) and drill the hole. Install the nut-sert with the tool and tighten it. It sort of was like a pop-rivet, but when you removed the tool, you had threads into which the hold-down bolt for the roof rack rail would install into. You need something like this for two reasons: (obviously) to keep the roof rack securely attached to the roof and also to have a water-tight attachment point on the roof so it won't leak. I'm not sure where you would get these nut-serts but a little Google-searching might turn up something. As far as the holes, get some measurements off of a Pathfinder with a factory installed roof rack. Position the roof rack on the roof fully assembled and mark the holes with a Sharpie or other marker. Measure twice and drill once! Once the hole is in the roof, there is not much to do if you messed up the measurements!