AstroSafariVans.com

I am planning a trip to a couple of Pick'n'Pulls, looking for a roof rack for my '98 van.
Are there any special tools needed ( like star bits or torque bits ), if I find one; or is it just the basic tools?
I would not like to get there and find some wierd fasteners.
Rod J
Issaquah, WA

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WE7X aka Rod Johnson
Forest Green Metallic '98 LS AWD
Issaquah, WA

Hi,

Been there, tried that. It is a big hassle since the fasteners are rusted in place.
Hammer, chisel, safety glasses, cordless drill and bits. Gloves be careful.

After not success trying to get old ones off in junk yard, I spent the $$ for the Rack n Road rail System where by they install 60" long rails using Riv nuts.
Then you can get Thule 460R podium mounts and cross bars.

AP

AP,
Thanks for the input. That is good information because I had not considered that rust possibility.

That Rack'N'Road stuff is very nice, but rather expensive, so I was looking for more economical options.
I occasionally haul long (15 to 20 feet), but very lightweight stuff, so the longer length of the stock rack has some advantages for me.
I may also look for a couple of extra stock cross bars for the original setup.
I just found a listing on E-bay for a used rack off a similar year, so I sent a note the the seller, with some questions.
Maybe I will not need to make a trip to the Pick'n'Pull.

Rod J
Issaquah, WA

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WE7X aka Rod Johnson
Forest Green Metallic '98 LS AWD
Issaquah, WA

Hi Again,

Yes if you could get a OEM rack it would be nice. Some of the Chevy Tahoe and even Chevy Suburban OEM roof rails seem similar to Astro. I once tried to get one from a Suburban because it was longer. There was a time when I wanted the rack to extend further forward . most oem cross bars don't go too far forward because they want to lower noise and aerodynamic drag.
You can get Riv Nuts and Riv nut setting tool from Grainger and from Master Carr.
Then with Riv Nuts you do not need to remove the headliner, but finding the best locations for drilling the holes occasionally means you miss the roof stiffener etc. Always been a bit reluctant to remove head liners because of potential damage to clips etc.

At lease getting an OEM Astro rack would allow you to measure the places to drill the holes for riv nuts.

Good luck.

AP

72" rails actually at 46" centers on roof, plus forward stand alone towers mounted with Riv nuts.

Total length about 72 + 18 = 90". Supports 4 or more Thule or Yakima cross bars.

AP

Rails plus forward stand alone towers

Astro roof 72" rail plus forward stand alone towers

It was hand tools for sure. Either phillips or torx (Maybe T15 or T20, lots of those elsewhere in the vans), IIRC. The problem I had when removing my factory rails(prior to the pop-top install) was that at least one of the factory rivnuts spun. Luckily, I had already dropped the headliner, so I was able to have a buddy put a pair of pliers on it.

Yes, the factory rails were also just screwed through the roof metal into small riv-nuts. 10-32 or metric approximation, IIRC.

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"My minivan is cooler than your bro-truck"
2003 Astro AWD Astrolander/ZMB - GTRV Top Transplant, 4" OLV Lift, NP233 T-case, evolving interior
1995 Safari GTRV Organ donor - gutted and gone.

I have my old one that I just don't have time to ship. I am near Tacoma.
You may still need to yard hop for the missing pieces. Have extra cross bars also.
get in touch if you want it. I made my own RR.

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Recovering hoarder