Pacifica Universal Crossrail Adapter

 I managed to damage my cross rails (don't ask…) and  while the mounts were intact, their proprietary rails are pricey…and the Amazon equivalent was weeks off from when I needed to make a trip.  The rails do not allow for or account for  direct use by a universal mount kit like you can buy from Harbor Freight or anywhere else.

Like with many of my car related designs, 3D printing to the RESCUE!!

This a design that doesn't aim to be pretty.  Doesn't aim to have filleted or chamfered edges.  Just print it and make it work for you.

HW needed to  complete the design:

- 1 M6 x 55mm socket cap (or similar) screw, preferably a stainless one.  (Outdoors, obviously…)

Slice the thing as-is with the widest part of the model on your build plate.  It does not need supports that way (don't bother with the recessed part for the M6 screw…it's easier to clean up the stragglers that drooped down from the overhang there than to get out most auto-generated supports.)  You will want to print this in something tough and STRONG with about a 60-75% gyroid infill.  I used PC-CF at 60%.  Partly due to it being some of what I have in hand, partly because it's some of the best that you can lay hands on and still be able to keep the price reasonable and be able to print it on most consumer printers.  I suspect any of the Carbon Fiber filled outdoors capable (e.g. UV rated…) filaments will work if you adjust infill accordingly.  Fiberglass filled Nylon or PC will work as well for this.

Once printed, you can directly use it or put some peel and stick craft foam on the bottom,. cutting out the center screw hole out of it once in place.  The top is the bottom of the “T” and the fingers inset on the top of the “T” are for the inside of the clamp and should face inward to the centerline of the vehicle roof.  Just drop the M6 screw in and mount it in the mount holes for the stock cross-bars and go to town- mount the unversals on the T's and lock them down to the T's.  Done.