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 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.