My Buick SUV didn't come with any cross bars. I saw a set on Ebay for about $120.00 but still, I'd have to figure out how to mount it to the roof rack I bought. A trip to the hardware store and $10.00 later, I came up with this setup which worked great.
This instructable took me 3 months to put together. Well, the actual project only took about an hour but I had to make sure it held up to all our Summer travel. Now that it's tested here's what I did.
Step 1: Cut the bars to length
The bars are cut from 3/4" electrical conduit. A 10' piece cost me about $2.00. I measured the distance between the roof tracks and added 6". I then cut 2 bars the same length.
The roof rack sits right on top of the cross bars. This particular rack has six bolts that protrude out. Accordingly, I drilled out 6, 1/4" holes in each bar. The holes at the ends are drilled all the way through so they can bolt together. To keep the holes in line i just measured and marked their positions along the seam of the conduit.