If you need to occasionally haul building materials, ladders, or other long and/or bulky items that won't fit in your aluminum roof rack system you can put together a wooden frame that can attach to your roof rack and hold up to 500 lbs of cargo using lumber, ratcheting roof racks, and carpet or cardboard scraps to protect the paint job.
Personal finance weblog Mr. Money Mustache shares how he put together a basic rectangle frame by screwing together 1-inch by 15-inch boards to the inside of the aluminum roof rails and then attaching cross pieces of lumber at the end of the rails to create a rigid square. Attach this to the aluminum cargo rack using heavy-duty ratcheting straps, and be sure to protect your paint job with carpet or cardboard scraps.
This will create a surprisingly-stable platform to carry up to 500 lbs (the wood will flex with the weight of the load). You'll have to drive slowly since it can be difficult to steer when the top of the vehicle is loaded down but it should suffice to get your building materials home from your local home improvement store. See the source link below for more photos and details.
A DIY Roof Rack: Make your Small Car Carry Big Stuff | Mr. Money Mustache
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