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Discussion Starter #1
So, I finally(!) found a set of actual VW cross bars for the wagon. Got keys made for them - yay, I can use them! And, so much nicer than the crappy (eBay?) "universal" bars that I started off with.
But, a conundrum: They're too fat to hook, say, ratchet straps to them (so I can, say, strap down a pair of ladders.)
So, I started thinking "someone has got to make eye bolts, that I can slide into the cross bars."

Anyone have any experience here? A couple that I found:
https://www.amazon.com/Rhino-Rack-USA-43178-Eye-Bolt/dp/B01N6N6P1O
and
https://www.amazon.com/Rhino-Rack-S604-Bolt-Vortex-Bars/dp/B004Z8SP82

Anyone know if either of these (or, eye bolts from elsewhere) fit B5/5.5 wagon cross bars?
 

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try McMaster-Carr, they have a lot of similar "slot" style clamps in their 80-20 style structural tubing/shapes, what size is the slot opening, would cut and paste but am illiterate with my Nexus tablet as to cutting and paste, should have brought my laptop!!!
 

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they have both english and metric sizes for/of their "erector set" style structural aluminum tubing (square extrusions)
 

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I've been eyeballing load stops for that. https://www.yakima.com/load-stop-t-slot
I have lugged a lot of lumber on my rack lately. Full 4x8 sheets of plywood, ~20 2x4s, etc. With ratchet straps, I just hooked the 2 ends together and looped around the end of the bar that is sticking out to keep the load from shifting. Holds up nicely.
 

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Discussion Starter #8

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And, those are the dimensions that I came up with, too. The inquiry was more along the lines of "hey guys, any pre-made solution that is known to fit?" (read: someone actually used it on their car.)

I like those T-nuts better than the Build-A-Bear solution that I've worked up at McMaster-Carr so far (with cchief's starting points.)
 

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I have Thule bars and found a similar fit problem - bought a couple of large welded steel rings at Home Depot and slip them over the ends of the bar and hook load straps to them. You might also be able to hook to the factory fore and aft bars that come on the B5 wagon. Big advantage to Thule is they can fit almost any car with the proper mountings - I've used mine on several vehicles with the same mounts.
 

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Got these the other day. Nice and solid. https://www.amazon.com/gp/product/B077MNY8NG/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

Also got some t-nuts, but their base is too thick for the inside of the rail. Trying these out soon:
https://www.amazon.com/uxcell-Stain...:2470955011&rnid=2470954011&rps=1&s=hi&sr=1-4
-OR-
https://www.amazon.com/dp/B077THPQ4...colid=PJ9LIO667KYG&psc=0&ref_=lv_ov_lig_dp_it

You guys, I swear. Making me spend money on all this small stuff. ;) whatever keeps the modding bug going, I guess :).
 

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Discussion Starter #13


T-slot fasteners: https://www.mcmaster.com/catalog/125/1990 (1 pack)
Eyebolts (need to cut to proper length, took a couple tries): https://www.mcmaster.com/catalog/125/1590 (1 pack)
Washers (to keep the eyebolts from digging into the cross bars): https://www.mcmaster.com/catalog/125/3338 (order 4)

Cut eyebolts to 'just long enough', paint in trim black. NOTE: I used the T-slot fasteners 'inverted', to improve clearance in the cross bars.
Slide into cross bars, tighten in appropriate position. Attach ratchet straps, and secure the load (for me, ladders.)
:thumbup:
 
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