I made these way back in 2002. finally have a chance to post up pictures. I've had these on for 8 years with no problems. Once in a long while, maybe a couple of times a year before a long trip, I check to make sure all the bolts are tight.
I leave them on year round. On long trips I also install my DIY wind deflectors to the front cross bar. I use a door kick plate as the wind deflector and bolt it on to the front cross bars. The holes are already drilled on the kick plate and line up with the holes on the cross bars.
I used three steel angle bars, the kind with riveted holes. These holes provide endless mount of points for hooking on bungie cords.
Wind noise isn't a big deal to me, so I haven't noticed any problems in this area.
1. 3 angle bars, about three feet in length
2. Plumbers tape
3. nuts and bolts to to fasten the plumbers tape to the factory roof rack rails.
4. optional wind deflector using door kick plate.
As a safety measure, I also filed down the sharp corners and painted on some black vinyl material in case I bump into the corners.
See pictures in next post.