OK, I posted a question about rusting roof racks a few days ago...and thanks for all the info.  My roof rack does not "clamp on" like the pre-99 models.  Its supposed to bolt in.

Now here's my question.  My '03 Tracker did not come with the factory equipped roof rack, but I have one now, and I want to install it.  The body shop is hesitant to drill holes in the roof to install it (for fear of rusting).  Funny thing is, I have never seen how the factory installs the roof rack.  If you have a 99 or later GV or Tracker and you have looked to see how its installed...HOW IS IT INSTALLED?  

Does the factory punch holes in the roof then pass the bolts through before the roof liner goes in?  
Are the bolts welded into the roof somehow?  
Is there some kind of mounting bracket?

I've got the two roof rails, with the little plastic caps that fit on the ends to hode the nuts and bolts.  I've got the rubber mounting pads.  I've gone to two Suzuki dealerships, two GM dealerships, a roof rack place and a Van & Truck Specialty Shop.  They all say they have no idea how to install this other than drilling the roof...but none of them will do it for fear of liability (rusting).  

So how did the factory mount it?

Hope this helps:

http://www.zukiworld.com/month_120102/feature_gearguide_calminiroofrack.htm


steveo

notice that the put on some rubber washers to insure the seal.