Noticing this, I decided to fabricate some new ones using a more modern material, composite PVC, which is very inexpensive and readily available at the local big box DIY store. (a 12'L x 1.5"x1.5" square runs about 20$ for two, another 20 for stainless hardware for mounting). Underneath the PVC, between the rail and the truck body, is a layer of rubber that comes in a roll for under 20$ and is used for lining the bottom of tool drawers. The rubber is permeable very similar to a diving wet suit but more dense, which lets the water drain and the air dry them through (as long as you dont over-compress them when tightening!). I used rubber-backed compression washers under the nuts on the inside, after pushing the bolt through from outside.
Here you can see a couple comparison shots of the new and old ones:
Here is how they look during the test mounting. They are white now but I will be covering them with "flex seal" rubberized coating (after a light sanding to give some tooth to the finish) so they will be black to match all the other details. Pardon the grey primer sprayed here and there, I am in the process of touching up the camo paint scheme and protecting some exposed areas (until I can remove all the paint and do a proper job of it someday.)
Notice the nice new paint job on the roof rack, which is now back on top of things after 4 years of waiting to get done.
I will be rewiring the front roof rack addition with LED bulbs in those holes to replace the halogens that were in there and not working.
I like the more chunky look of the rails vs. the older size. Remains to be seen how they hold up, but I imagine they will do well. I have used the CPVC material before for window frames and trim, its very workable, not as hard as industrial nylon or ABS, but nearly 1/10th the cost. If they do get damaged, not hard to replace, I have spares set aside.
