How To- Waterproof Rooftop Storage Boxes Securely Mounted On A Roof Rack

How to install waterproof storage box on roof rack for overlanding. Quick release rooftop cargo box on a Toyota 4Runner, but they can also attach to aftermarket roof racks on a Tacoma, Jeep, Subaru, truck, anything with a flat crossbar. We use large Plano gun cases, or rifle case, but any plastic or aluminum gear bin can be mounted the same way. Our DIY method mounts an inexpensive waterproof storage case securely and safely to our roof rack bars.
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Items below were sourced from McMaster-Carr: www.mcmaster.com/
6- 92311A544
18-8 Stainless Steel Cup-Point Set Screw, 1/4"-20 Thread, 1-1/4" Long.
1- 7062T23
Multipurpose 6061 Aluminum Z-Bar, 1/8" Wall Thickness, 1-1/8" High, 1-1/8" Outside Width, 3 Feet Long.
1- 1466N32
High-Temperature Silicone Rubber Strip with Adhesive-Back, 1" x 36", 1/16" Thick.
Items below were sourced from Amazon:
6- 80/20 Inc, 3686, 15 Series 1/4-20 Centered Slide in Economy T-Nut: amzn.to/3k9dKHy
1- Lee Engineering Aluminum Lab Frame Lattice Rod 1/2" Diameter X 36": amzn.to/3drLiPU
1- SBDs (Pack of 10): 1/4"- 5/16" Round Black Vinyl Flexible End Cap Bolt Screw Rubber Thread Protector Safety Cover | for 0.250 Inch Pipe Post Tubing Rod OD Cover - 1" inside Height: amzn.to/3auyZjN
2- Plano Mil-Spec Field Locker Tactical Long Gun Case with Wheels: amzn.to/3pyHLBE
Items below were sourced from Lowe's:
8- 1/4" 20 x 1" stainless steel bolts
8- 1/4" 20 stainless steel nylon lock nuts
6- 1/4" 20 wing nuts
1- 1/16" x 1" x 3' aluminum flat stock
1- 1/8" x 1 1/2" x 4' aluminum flat stock
Pulled out from under our workbench:
An old rubber semi trailer mudflap.

[@MRAPLUS]

I came right here when I needed a roof storage case.. Thank You Guys..

[@WanderlostOverland]

You're very welcome!

[@SHWELL11]

Ive done similar with less expensive Plano cases with success, so there is a more affordable option available to those that cant afford to spend $150 in that particular Rifle case. Plano has many options for everyones needs.. Great video and thanks for sharing.

[@paulwhitaker6025]

Great install. I felt the same way, drilling holes into a 150$ case but it’s cheaper than getting a storage Thule. Way cheaper and more rugged!!

[@mmmmmmb]

Just found your channel after I bought a 4runner and wanted to set up a family overlander You guys are incredible. I love the creative engineering. My 4runner project list was crossed off quickly with the guidance of all your great videos. Natural teachers.

[@WanderlostOverland]

Thanks for watching!

[@Jorgeeeehhh]

The quick disconnect system you guys came up with is ingenious! Love this channel

[@willpowell2938]

That look he gives the camera at 4:39 as well, he knows how slick that is!

[@paulf9653]

Nice and simple. Now I just need an SSO Roof Rack. 😁

[@WanderlostOverland]

Thanks for watching Paul!

[@photog1529]

I may not have a Toyota ('95 4WD Suburban), but I get a lot of enjoyment from your videos and learn a few tips as well. By the way, those cases are no longer $150 🙂

[@veedubya4636]

I enjoyed the video and I really like this idea! Now I have to get an roof rack for my FJ.

[@BarlitosC]

3:30 got me

[@BarlitosC]

what

[@InGratitudeIam]

This is the smartest approach I've seen yet. Thank you.

[@WanderlostOverland]

Glad you think so!

[@daledurham7353]

I've been using these for years! Secure and waterproof with a very low profile!

[@MrGenerichead]

Why not use the studs in the back also in the front? Great concept!

[@kypercarjoe153]

I love the witty and love you share. God bless and keep us laughing. Great stuff.

[@jeff9104]

I haven't got my 4 Runner yet but I watch all of your videos for future add-on mods, thanks

[@WanderlostOverland]

Thanks for watching Jeff! Let us know details of your 4R build when you start it.

[@meharsamba]

This was surprisingly well elaborated.

[@vy10mac9]

Really great for the price

[@TrailorSailYT]

I always love Mary's facial expressions when she gets called out. LOL

[@14chstr]

How's the aerodynamics? Can you hear or feel the air dragging the box when driving?

[@erikaamac2727]

THANK YOU FOR YOUR DETAIL!!!

[@mikehoffman3690]

Ingenious design. We’re going to explain it to you. 🤣

[@WanderlostOverland]

Thanks Mike!

[@AustinLWright]

I love this channel. You two are hilarious.

[@aaronhodgdon]

Great video and application... One question, in the parts section of the video description you list Lee Engineering Aluminum Lab Frame Lattice Rod 1/2" Diameter X 36"..... Where was this used in the video?

[@WanderlostOverland]

I'm sorry, that was used to make the traction board pins.

[@davidellenbaum1229]

nice job taking your guest for a ride .so funny

[@WanderlostOverland]

Always reluctantly cooperative! It's like she knows us or something.

[@Bergo101]

Thanks for the video. Wondering why you’re not just using ratchet straps? It’s easy and very sturdy, flexible in where you position the box, cheap and so on. Just curious!

[@trailrunnah8886]

Excellent! Very clever. I'm going to look into seeing if this is possible on my stock rails. I've been thinking one or two of these cases may come in handy.

[@WanderlostOverland]

Thanks for watching Michael!

[@patricioelosua5886]

Managed to find this video after clmmenting on the FJ vs 4R video haha. Thanks!!

[@WanderlostOverland]

Great to hear!

[@RenegadeAdventuresNC]

GENIUS! Thank you!!

[@michaelbahl4357]

I want to try this DIY solution out. The Amazon link for the box is broken could you update it?

[@nestorcarrasco]

I like a lot your sense of humor! ;)

[@WanderlostOverland]

Thanks! 😃

[@xtiantv7168]

The best part is when their daugther VOLUNTEERS to have adventure with them 🤣🤣🤣

[@therealsolo23]

Great idea. Best one ive seen yet.

[@WanderlostOverland]

Glad you liked it!

[@user-tr7gl9ue9r]

Could you mind of giving a clue of purchasing the storage box? It's so hard on researching google.

[@StansE250]

How do you secure your boxes from Prying by n’er do wells who want (inside) ?

[@WanderlostOverland]

The boxes have a place where we can use a Padlock

[@greeenteeee]

What have you carried in there? I like they are low profile but not much you can store in there id imagine

[@WanderlostOverland]

We put a tent, tarp, and poles in one. The other gets misc. camera equipment.

[@independantish]

The ruf .. yes

[@rickdoesitforyou]

Any vibration?

[@WanderlostOverland]

Nope, none at all.

[@MM13916]

Great video! Love your content and its helping my build come along. Question: Is there a reason you went with the Z bar mount in the front, rather than another set of 3 bolts / wing nuts? I see that you like being able to pull the cases off easier with the Z, but seems to me they would be odd to store with that extra metal on the bottom (when not in use on the 4R). Thanks!

[@WanderlostOverland]

Thanks for watching Anthony! Our primary goal was to make the boxes as easy as possible to put on and remove. Unfortunately you're correct, the bars do make it somewhat less convenient to store when they're off the top.

[@MM13916]

@@WanderlostOverland thanks guys! Love the setup and probably going to try one box with the Z bar and other just bolts to see a difference. Love your videos and have watched the SSO bumper install a few times. I’ll be putting mine on next week, thanks again for such great content

[@madcratebuilder]

Very nice hold down hardware.

[@WanderlostOverland]

Thank you!

[@overlandadventures6763]

Great video. I'm going to follow your example and do the same. Thanks for all the great content. Love your channel

[@WanderlostOverland]

Awesome! Thank you!

[@RedDevilTuning]

Can you show how to add struts to the box?

[@willpowell2938]

Great video, working on doing this! One question, what are the lattice rod's used for? I don't recall seeing those in the video, but they're listed in the supplies.

[@WanderlostOverland]

I'm sorry, I forgot to take the lattice rod off the list. That's actually used to make the traction board mounts.

[@willpowell2938]

@@WanderlostOverland No sweat! Love the videos, keep them coming!

[@mykalbee]

Looks good. I am curious to know what if any hit to the fuel economy there is?

[@davidellenbaum1229]

better fuel economy !funny guess your 4runner doesn't get good gas mileage .travel down hill !

[@WanderlostOverland]

There'll definitely be a reduction on mileage. But 4Runners aren't known for fuel economy anyways.

[@AllThingsOverlanding]

Great video as always guys! Great idea too!

[@jpperez4716]

Love the idea and execution. Thank you

[@WanderlostOverland]

Thank you!

[@melortega6228]

Mark and Marri, I love all ur budget friendly mods to ur RIGS...i do alot of mods on my FJ myself from watching u guys ,thank you for the toturial.Now,I have a? which RIG do u guys prefer the FJ or the 4Runner?I mean there both beautiful.thank u GOD BLESS and BE SAFE.

[@WanderlostOverland]

Thanks for watching Mel! The FJ is our favorite just for its cool factor. But the 4R has more interior room, better creature comforts, and we can see out of it.

[@juanpastor]

Your shopping list shows 1-3ft zbar. Any reason you couldn't do it with 2-1ft zbars? I'd like to minimize the amount of cuts. Thanks guys, I appreciate the thought that goes into you videos.

[@WanderlostOverland]

You can definitely do it with 2-1' bars. We like to get extra stock, just in case we screw a piece up.

[@coolspot18]

This is a good idea to use a gun box ... any issues with noisy people wondering why you're driving around with so much "hardware" on the roof? I'm looking for a low profile solution myself but worried about people freaking out.

[@WanderlostOverland]

Most people don't even know what they're used for. So no problems there.

[@markmissildine8345]

It nearly kicked my butt on the TRD ROOF RACK, but finally got it done.

[@rostamr4096]

Another great video...thanks guys..

[@WanderlostOverland]

Thank YOU for watching!

[@cephirof]

LOVE ITBest of others

[@flapbean]

Darn it. Wish I saw this video before cutting extra holes in my Pelican gun case 😞

[@dimascuevas5834]

Great video!

[@WanderlostOverland]

Glad you enjoyed it

[@mdtran07]

Great video! I have a question, would a 1 inch Z bar work as well or not? TYIA

[@WanderlostOverland]

It should

[@officialWWM]

Those boxes are awesome and exactly what I’ve been looking for. They are pretty darn expensive though :/

[@WanderlostOverland]

They are!

[@InGratitudeIam]

Buy once. Cry once.

[@officialWWM]

@@InGratitudeIam I’m in Australia…that automatically makes them $200 more expensive here!

[@zman92630]

Wow, great video (and great sense of humor, guys!) I love how you find a way to make it work, with a little creativity! Also, like most of us, you don't want to pay Yakima $40 for one tiny little part. Thumbs up! Sub +1

[@WanderlostOverland]

Thanks so much!

[@soldermecold7456]

Nice work, I got pelicans on my roof. The case, not the bird.

[@WanderlostOverland]

Sweet, we've been using Pelican cases for our camera equip. for many years. $$$

[@OverlandTrax]

Nice video, keep them coming ✌

[@miltonparker8353]

Drill holes, U bolts...Like how Packasport does it, simpler

[@pinoyrc77]

Nice video, what brand is the cargo case and model thanks I appreciated

[@WanderlostOverland]

They're Plano rifle cases and come in a wide range of shapes and sizes.

[@pinoyrc77]

Thank you sir I appreciated

[@flisms]

Very nice!!

[@WanderlostOverland]

Thank you! Cheers!

[@BarFlyFishingTexas]

Love the video! You guys are funny!! Refreshing! New Sub here! #BarFlyFishingTexas

[@WanderlostOverland]

Awesome! Thank you!

[@jotsingh8917]

Hah, great install but more challenging for the standard OEM 4Runner cross bar....

[@_beez33]

Do you use a ground tent instead? If so, which one?

[@WanderlostOverland]

Yes, we have several. We have an REI tent, a canvas baker’s tent with wood stove, and we have a 1963 Hiawatha camper that we took off the frame and completely restored. It all depends on where we are going and what the weather and terrain are like.

[@Bookerdevin101]

I'd choose Pelican cases though

[@NigelNaughton]

Awesome!

[@WanderlostOverland]

Thank you! Cheers!

[@damenjacobs]

Are there any Over-landing meetups in the Midwest worth going to? I live in Illinois and it seems like everything is West/East coast lol. Also any good trails located in the Midwest for beginners?

[@joshuawilliamson7672]

Damen Jacobs Colorado and Pennsylvania are probably the nearest for you

[@WanderlostOverland]

Northern Wisconsin and Michigan's UP has tons of Forest Service roads and trails. Then there's Land Between The Lakes in KY. Plenty of places to explore if you're willing to drive 5 hours or more.

[@BirdDogOffRoadAdventures]

Damen Jacobs I recommend spending some time at River road Rally or Badlands off road parks to get familiar with your rig. There is the KOAR event in the UP every year and MOOR in Missouri. Chitown 4X4 has events every so often as well if you want to follow them on Facebook. As Mark and Merri said there is also Land between Lakes in Ky and there are also trails in the Ozarks that are pretty popular.

[@TerryGrayTX]

Uh oh...looks like SSO might have changed their extruded aluminum since this video. Even though video is not even a year old yet, i knew I should have measured and verified 1st! My T-Nuts (or T-Slot Nuts, for some people) just arrived and they are too big. I'll snoop a bit and see if I can confirm and/or get an updated part # from 80/20 (and Amazon link if they sell it there). Link to photos: photos.app.goo.gl/9g21rxcxg3z5Q2cEA

[@TerryGrayTX]

Got these in today, and looks like these will work: 80/20 Inc, 3382, 10 Series 1/4-20 Centered Slide in Economy T-Nut (25 Pack) www.amazon.com/gp/product/B00JF7AIEM Others may fit as well. Key thing might be to get 10 Series instead of 15 Series...but you better check your crossbars 1st. BTW, I got my SSO rack in late Sept 2020

[@bravovictor1922]

What are you gonna do? That sounds naughty

[@cash1469]

Why you guys so so funny, hahahahahahahahahaa

[@TheTorkerman]

You guys are funny

[@jotsingh8917]

Wrong: The T-slot nuts are not sliding into the rail unless they are filed into the proper trapezoid shape. Further, I find it ridiculous that SSO does not these items in their offering. This racks looks good but the detail engineering leaves much to be desired. Would not buy again.

[@chriss8206]

I'd choose anything that didn't look like a gun case. There's other options.

[@cephirof]

LOVE ITBest of others