2003 Chevrolet Tahoe Low Profile Overlanding Roof Rack

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The main reason I bought my 2003 Tahoe was to get into overlanding. I have done some other work to the vehicle but quickly realized that even though it is a full size , there was not enough room on the inside of the vehicle and I decided I wanted to put on a roof rack. I browsed through what felt like hundreds of webpages and forums trying to find a low profile option that didn't just put a basket on the load bars. I was really looking for a design that used the extruded aluminum crossbars but eventually I realized there was nothing available that met my needs (wants?). So, I decided to design and build it myself.

I started with removing the stock load bars and side rails to see how they were attached. GM used 5 rivnuts on each side bar to mount them to the truck. After brainstorming some options I decided to purchase some L-track to see how it might work as a mounting base for new brackets and side rails.

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In these photos I have laid the L-track and some crossbars on the roof to try and figure out if it might work. I found that there is a slight mounting width difference between the front, middle and rear mounting holes for the stock side rails but I was able to use 2 holes on each side of the truck that I could use as a reference to mount the L-track.


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Because I did not know what the structure of the body and roof was like, I pulled off most of the interior panels to see if I would have any issues drilling additional holes through the roof to mount the L-track
 

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I very much enjoy your post! I started overlanding myself with a 2008 Denali. I found the OEM Denali rack useless and bought a 2005 Z-71 tahoe rack and it mounted right up. It's beefier than the standard rack and allows for some mounting options. I put on a rooftop tent.

I totally wanted to do what you are trying, but didn't have the time to figure it out. Keep us (me) posted on your progress. It's cool to see people starting to use GM stuff besides Toyota and jeep. Overlanding is pretty fun!
 

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Once I was able to look at the inside of the Tahoe, I decided to go ahead and mount the L-track to each side of the vehicle. I started by lining up the L-track with 2 of the factory mounting holes and used the L-track holes as a drill guide for adding the next 2-3 holes. I took the track off and drilled out the pilot holes to accept 1/4-20 stainless steel rivnuts. I installed the rivnuts using a tool I purchased off Amazon and applied some paint and sealant to each hole. I repeated the process of lining up the L-track and adding additional holes until I had about 6 and a half feet of the L-track mounted.

I don't have any pictures of this process but I drilled something like 20 holes per side. Once I had all of the holes prepped, I cut and painted the track then added 1/8 inch thick self adhesive foam to the bottom before attacking it to the roof with 1/4-20 stainless steel screws. I used acid etch primer and raptor liner.

Once I had the track on, I was able to determine some of the angles of the roof line and measurements. I used the information to design and get some brackets cut out of 3/16 inch think aluminum. I added a slot to accommodate to difference in width from front to back and made it wide enough to take a 3/8 inch fastener which is the stud size for L-track.

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I test fit the brackets and did some additional measuring to see how long I wanted to make the side rails. With the brackets on the L-track, I used some extruded aluminum to determine a parallel line referenced from the side of the truck to ensure the rack didn't slope up or down awkwardly.

Next I used some wood and took measurements with the roofline to get all the dimensions I would need to design the side rails.
 
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I drew up the side rails and had them cut out of 3/16 inch aluminum. I had to have a split in the rail due to the bed size which is why there is a joint in the rail.


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Here are some pictures of lining everything up to get ready to drill holes in the side rails for the brackets to mount to the L-track.

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Thanks!! I have most of the rack done but just need to get an air dam measured and cut.
 
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After I had everything lined up I verified that I hit my mark of having the cross bars be a 1/2 inch from the roof at the closest.

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I went ahead and drilled my side rails and did another test fit.

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Because I didn't know exactly how everything was going to line up initially, I had made the brackets taller than they needed to be so I also cut them all down to fit.

I then got back to work and sanded the side rails, brackets and hardware down to get it ready for some acid etch primer and some flat black enamel paint. I decided to use enamel because I did not want the textured finish interfering with the mate up of pieces and hardware.
 
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Once I got everything painted I assembled and attached it to the L-track.

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I think I did pretty good when it came to following the body lines on the side rails and choosing my angle to follow from the windshield. As the rack sits right now, without an air dam, there is no whistle or wind noise coming from the rack what so ever.
 
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I designed the rack to have a crossbar on standard 12 inch spacing to accommodate a lot of roof rack accessories (such as the GMRS antenna mount) but it has a variety of spacing options to use. The hard spacing is done at 6 and 12 inches with an adjustable slot in between those. There is also some hard spacing done at the front and rear of the rack as well as the angled portion.

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I plan to finish up the air dam in the next month or two which will include some sort of solution for limb risers.
 

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I wanted a roof rack on my fiberglass shell. I didn't like the 'bulky' aftermarket designs. ( large brackets & had an industrial look )

It took a bit of looking around for ideas. I then saw the "quick - mount" surf board / camping rack kits, for a typical car roof. I bought a kit. Tossed out the 'roof-edge' mounting hardware. I through bolted the surface mount with 3/8" stainless bolts. The rack bar is solid aluminum, with a nice very slight 'curve' ( right-to-left ) that hugged the shape of the roof, as if it belonged there.

It held a 40' extension ladder, etc. The rack was almost invisible, if you weren't looking for it.

So,.... search for 'strap-on roof racks"...... Maybe you will find one that can be fabricated like I did.

( I miss my great old truck..... Sold to a collector in Germany )
 

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