Unistrut Rack For Ford Transit 2015-up

I needed a roof rack to mount a pair of solar panels on my 2017 Ford Transit (148" mid-roof standard length) and used some half-height Unistrut leftover from a previous project.  The rack attaches to the factory threaded inserts built into the roof structure of the van that hide under plugs in the roof skin. This is only for the rearward pair of inserts just ahead of the back doors; while the feet may also work as-is for the more forward positions I did not try it or even check.  STEP files are there for easier modification in a real CAD package, if you use something like Meshmixer you're on your own.  

The foot blocks themselves are separate from the angled spacers, and the spacers are needed because the roof surface at the mounting spots is angled.  I used 5 degrees which turns out to be not quite right but it's close enough that it works, 5.5-6 degrees might be better if you want to play with it.  The spacers are separate pieces from the foot blocks partially to have only one block for both the LH and RH side, and also so the spacers can serve as gaskets if printed with TPU.  There are also corner spacers, these I made to help keep the cross pieces aligned during assembly but are not strictly needed.  The fore-aft sections of Unistrut are bolted through the foot blocks and spacers into the roof and the side-side sections are bolted to the fore-aft sections, so use good quality hardware with washers large enough not to slip through the slot of the rails.   

The bolts I needed to attach these to the roof are M8-1.25 X 80mm long, with 25mm OD washers.  3M 5200 sealant was used on the underside of the spacer/gasket to the roof, the underside of the foot to the spacer/gasket, and also on the underside of the bolt heads and washer to provide extra sealing for peace of mind.