Mounting A Rooftop Cargo Carrier To The Roof Of Our Van. Now we have the base frame for our Roof Rack done, we need to install a Rooftop Cargo Box on top of our ProMaster Van. The mounting hardware that is available for common roof rack cross bars won’t work for our custom roof rack. Fortunately, UniStrut Channel Metal Framing Systems are very versatile and allow for many different mounting options.
Keep reading to see the configuration we use when…
Mounting A Rooftop Cargo Carrier To The Roof Of Our Van
We already have an older model Thule Frontier, but if we were in need of a new box, these are the ones we would consider.
Brands Of Rooftop Cargo Carriers Worth Considering
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Yakima
The Yakima Skybox is available in multiple sizes as well as a low profile option. The dual-sided opening means you have more possibilities for install. Not to mention how sleek the Yakima Skybox looks with its aerodynamic shape.
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SportRack
The SportRack Skyline XL Cargo Box is another popular choice among rooftop cargo carriers. The shorter length means more room for other roof-mounted accessories
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Thule
Last, but not least, if we had to purchase a new rooftop cargo carrier, we would choose the Thule Force XT Rooftop Cargo Box. Its narrow design allows for install beside a Roof Vent Fan.
How To Attach A Rooftop Cargo Carrier To Our Unistrut Van Roof Rack
Unistrut Kwik Washer
Our local wholesale store had these things in their strut channel selection. The integrated washer and nut assembly seem like a great idea. Unlike the all-plastic smart nuts, the Unistrut Kwik Washers means there is no need for a top mount bracket. Another way to simplify installation
Aluminum Stand-Off
It is hard enough to line up bolts when standing on a ladder and leaning over on to the roof of a van. To help with this we wanted to have access to the channel under our cargo carrier for possible tie-off points as well as to make installation a little easier. We figured some 1x.25 aluminum pipe would work nicely!
Incorporating Thule Hardware
To keep the designed strength, we incorporated some of the Thule factory mounting hardware. Our old Thule Frontier uses these galvanized metal plates to sandwich the plastic base of the carrier. 
Clean Up The Old Hardwear
We drilled out the original ¼” holes to fit our new ⅜” bolt, then gave them a light sand.
#ProTip: De-glossing any shiny metal with scratchpad helps the paint to stick better. (No need for etch primer)
Spray Painting
To keep with our black and grey color scheme, we gave all the parts two coats of rust paint.
#ProTip: Hanging your parts on wire will help to get a professional run free finish. 
Fasten The Sandwich Plates In Place
We used ¼” bolts and locknuts to bolt the Thule mounting hardware in place. Now our ⅜” bolt has a secure and solid mounting point!
Installing Our Thule Van Rooftop Cargo Carrier
Now all our hardware is prepared, it’s time to bolt-on its time to Mount A Rooftop Cargo Carrier To The Roof Of Our Van
Step-1 And Done ✅ 😂
Now that the rooftop cargo carrier is mounted and ready for us all we need now is a way to access it. 🤔 Look out for some more on this in the near future.
Interested In Some Of Our Other Cool Van Projects?
- Mounting Robe Hooks To Our Van UniStrut Rails
- Installing Our Van Mini Safe
- Van Window Trim
- Campervan Kitchen Pod – Mini Prep Area
Check Out These Other Exterior Projects
Thanks for reading, and remember to always take the road less traveled!
Weekender Van Life – Van Life Blog – weekendervanlife.com
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