BigC9164

Got a set of factory roof rails off of a 91 XJ at the junk yard. Prep/painted with some rustoleum flat black enamel.

Purchased the COOLEST tool on the planet. Harbor Freit threaded nut insert tool. http://www.harborfreight.com/45-piec...-kit-1210.htmlNot the best quality but it worked. I ordered some 1/4-20 ZINC coated inserts from amazon. Hopefully will prevent rust as best as possible. I could not find any stainless inserts with the crimp dimples on the outside of the insert like the factory ones had.

Drilled some 23/64 " holes. touched up with paint. Dabbed some clear silicon adheasive on the insert and pressed them into the roof. Bought new grade 8 hardware and installed the roof rails with an allen wrench. Also put down an extra circle of silicon around the nutserts. And laid down a bead of silicon on the inside of the rails. I doubt any water will get through but I will keep y'all posted after a few months. Here are the pics.

Ralph77

Rivnuts are pretty cool. I have to remove my roof rack to get some work done to my roof on my '00. I am just going to assume it will not come off easy and will have to replace a rivnut or two or ten. Also thinking about buying new bumper caps and the front valence. Instead of riveting it in like from the factory using rivnuts there too.

BigC9164

yeah i would trust rivnuts as long as you get some quality ones. the rivnuts that came in the harbor freight kit were a joke. As were any i could find at the hardware store. The zinc coated ones off amazon were great however. If it makes you feel better, the junkyard rack came off super easy! i just recommend using a hand screw driver to remove the 12 torx bolts. If you break the crimp free of the rivnut i bet it would be a bear to remove.

abodyjoe

may be surprised. the roof rack on my 00 came off very easily.

BigC9164

I used one of the grade 8 bolts i used for this project and tried to pry out the first rivnut i installed to see how strong it was. Turns out is it very strong. I used these rivnuts from Amazon:
I made sure they were crimped 100% on the roof sheet metal. So unless the sheet metal tears I am very certain the roof rails will hold with all 12 bolts tight. At least it will hold better than the factory roof rack cross bars. They are a little flimsy. The plastic brackets that hold the cross bars to the rails at least.

Ralph77

Hope your right. I removed my headliner to have it done about a year ago. Wish I could remember what it looked like under there. Thinking I would remove it again. Soak all the torx with PB Blaster, removing the headliner just in case it could leak in on it, and see how it plays out. If I have to replace some of the rivnuts I hope I can fish them out. Hate to have the bottom half of the rivnut, after grinding off the top half to get it out, rattling around in the roof for the rest of time.

Ralph77

Finally pulled the roof rack off. Without a hitch. To be frank the rivnut screws were barely tight. Not that I am compaining. Not usually that fortunate.

x-mann

Hi, I'm a new member and I read your post. I'm curious: how difficult was it to install the roof rack? And...how's it holding up? Any leaks? I purchased a 1994 XJ base model with no factory rack and I'd like to have a rack installed but cannot find a shop willing to do the job.

318SixPack

Might want to use 3M urethane seam sealer or the white Permatex thread sealer on those inserted threaded nuts, rather than just plain old silicone.

x-mann

Thanks for the tip. I was not aware.