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The rack bracket holes are each measured from the rear of the roof where the metal trim meets the body.
From the rear, the rear bracket holes are 2" and 5 3/8"
The middle bracket holes are at 30 3/8" and 33 1/4"
The fronts are at 58 1/8" and 61 3/4"
The bracket screw hole distance from the drip rails are measured with a cloth tape following the roof curve and are 6 1/2" in and the fronts are 6 1/8" from the rail. Obviously the main bars are the same width apart and this difference is due to the sloping drip rail.
The bases of the factory brackets are offset outward from the main bars by approximately 1/2" center to center on each side.
Width of the cross bars at the flats of the nut face is 44 5/16"
The main bars are 1" wide with 44 3/8" inside to inside edge width and a total length of 59 3/4".
The outer edges of the bars are at 46 3/8"
Lastly, the bracket screw hole widths C2C of 3 3/8" at the rear, 2 11/16 at the center and 3 1/2" at the front.
Too Much Info, but I provided it so you have it all.
Jim
1977 Cherokee Chief - The Blair Jeep Project III
A collection of parts flying in close formation
The main bars are 44 3/4" apart center to center.
If you are referring the the cross bars, they are adjustable and can travel the full 59 inches along the inner channel of the main bars. I added a third bar and centered them over the mounting brackets which works very well for lumber and stacks of plywood.
Since you are fabbing up your own, I would suggest you place your mounting brackets in the factory location as these three areas are stronger. I would place 5 cross bars evenly spaced from center to the ends of the main bars if I were fabbing one up for myself.
Since it sounds like you are going to construct it with welded tubing, you won't need to worry about adding the roof stiffener strips. The factory bars would bend under weight and rest on the roof which was noisy and made for bouncing cargo.
1977 Cherokee Chief - The Blair Jeep Project III
A collection of parts flying in close formation
I don't know squat about roof racks except for the pre 74 hole spacing is way different than the 74-91 spacing.
But again, i never did any real research about this.
I'm just joking of course.
About 100 of us did awesome research on this, most of us before many of you became web members.
It's all online and searchable.
I will say, the factory mounts for pre 74 racks were simply sheet metal screws into the roof.
Piss poor design.
The 74-91 mounts are what we typically call well nuts, another piss poor design.
I will get heat for this but i would not carry a skate board up there on 30+ year old well nuts.
A collection of 1966 to 1986 parts. Self Inflicted Flesh Wound
Caddy425/TH400/Atlas 4spd/14B/D60/locked front and rear/Hydroassist/39.5 Irocks (Join date = Friday the 13th)
Lol, yeah, grandpa. I've searched da net and both forums on measurement specifics are kinda lacking, but I've found plenty about reinforcement plates of stock racks. I'm not doing a stock rack on the panel.