How To / DIY: Touring Roof Rack – Thule Tracker 430 with TK2 foot pack

[stilljester]

This project took me about a bit more then a 1 hour so it makes for a great lazy Saturday project. Thank you to Hopefully this will help someone else out this is what you’ll need:

Thule 430 Tracker Feet
TK2 Foot Pack
Set of Thule Bars
Qty 8 – 6mm x 20mm Cap Screws


Note: You could use a TK1 foot pack and avoid having to sand them down flat or having to cut up the flats that I did. You’ll still need to modify the flat face to avoid interference from the factory rails. However after watching these on eBay for several weeks the Tracker 430 Feet with TK1 foot packs are averaging $90 to $120 where a Tracker 430 kit with TK2 feet are only $40-$60. So I went with the TK2’s Truthfully I think you could use any of the TK foot packs. Thanks to 530iTouring for helping figure out the differences.

You’ll need a belt sander – nothing fancy but a nice belt sander will make your life much easier. I used a 120 grit Aluminum Oxide belt.
http://images20.fotki.com/v373/photos/9/925706/4428706/pic1-vi.jpg

Before Sanding
http://images14.fotki.com/v363/photos/9/925706/4428706/pic8-vi.jpg

The feet are a 30% glass fill so the 120 grit cuts them nicely
http://images14.fotki.com/v363/photos/9/925706/4428706/pic2-vi.jpg

Take the foot and orientate its back flat against the sander so that the foot is perpendicular to the belt
http://images14.fotki.com/v363/photos/9/925706/4428706/pic3-vi.jpg

[stilljester]

Sanding – Keep the foot level as it removes the material
http://images14.fotki.com/v363/photos/9/925706/4428706/pic4-vi.jpg

Nice and slow
http://images18.fotki.com/v375/photos/9/925706/4428706/pic5-vi.jpg

Sand down until the entire surface is flat – you will need to stop every 10 seconds or so to clean off the extra material which is being removed.
http://images20.fotki.com/v366/photos/9/925706/4428706/pic6-vi.jpg

Completely Sanded
http://images14.fotki.com/v363/photos/9/925706/4428706/pic7-vi.jpg

[stilljester]

Comparison between original and modified
http://images20.fotki.com/v369/photos/9/925706/4428706/pic9-vi.jpg

Another View
http://images18.fotki.com/v375/photos/9/925706/4428706/pic10-vi.jpg
Next you’ll need to sand off a bit of the center face so the rack will fit squarely to the rail. You’ll only want to sand up to the mold line on the part.
http://images20.fotki.com/v367/photos/9/925706/4428706/pic11-vi.jpg

Sanded
http://images20.fotki.com/v369/photos/9/925706/4428706/pic12-vi.jpg

[stilljester]

Next you’ll need to cut the supplied mounting brackets down to fit the BMW channels
http://images20.fotki.com/v369/photos/9/925706/4428706/pic14-vi.jpg

Cut off the threaded face about ½ inch long. The width is fine just cut the piece down small enough to fit inside the mounting hole.
http://images14.fotki.com/v363/photos/9/925706/4428706/pic15-vi.jpg

You’ll need some longer cap screws
http://images14.fotki.com/v363/photos/9/925706/4428706/pic16-vi.jpg

Install the front end first
http://images18.fotki.com/v375/photos/9/925706/4428706/pic17-vi.jpg

[stilljester]

Insert the rear flat now
http://images20.fotki.com/v366/photos/9/925706/4428706/pic18-vi.jpg

Tighten
http://images18.fotki.com/v375/photos/9/925706/4428706/pic19-vi.jpg

Cut and reinstall the rubber seal
http://images14.fotki.com/v363/photos/9/925706/4428706/pic20-vi.jpg

Close up of installed Tracker 430 with modified TK2 foot
http://images14.fotki.com/v363/photos/9/925706/4428706/pic21-vi.jpg

[stilljester]

Finished Rack - Enjoy:)
http://images14.fotki.com/v363/photos/9/925706/4428706/pic23-vi.jpg
http://images18.fotki.com/v375/photos/9/925706/4428706/pic24-vi.jpg
http://images20.fotki.com/v364/photos/9/925706/4428706/pic25-vi.jpg

[Elekta]

Archive in FAQ's.

First rate presentation. Looks exactly like my setup. Best part of this set up is the quick connect feature. Now all you need to do is get new load bars and feet for each setup and hang them all from the ceiling in your garage. Pull under it, crank down, load and go.

I have different bar spacing lengths for the windsurfers, so I cut my rubber inserts to fit my most used load bar set up which for me is the Evo 1600.

Also, those nuts that sit in the rails rust pretty quickly, so some preventative grease or something helps a lot. I also made little plastic protective gaskets for between the top of the rail and the footpack to give the footpack something to dig into when tightening. DO NOT OVER TIGHTEN as the footpack will break. No need necessary to ask how I figured that out.

Great write up. This set up is like (what one friend told me after he gave implants to his wife after their third child) ..the gift that keeps on giving.

rack it

http://www.bimmer.info/bmw/ggil/Thule%20Toys.jpg

[brosher]

Excellent write up, thanks.