So I finally got around to installing the thule roof racks this weekend. I thought I might post some instructions for those of us who have SE's and would still like to have a roof rack.
First off Thule makes a 42 inch track and a 54 inch track. The model numbers a TP42 and TP54. I bought the 54 inch track because I thought that I could put on slightly more that 42 inches of track on my crew cab and I could just trim down the 54's.
My first piece of advise would be to buy the 42 inch tracks. I aligned the tracks that I bought (54 inches) with my roof and trimmed it off to how long I wanted it. When measured the tracks that I cut they were 42 inches. So basically I wasted a few bucks buying the larger tracks but it was a good learning experience.
Then I lined the racks up on my roof. I put masking tape in sort of a grid on the roof to make sure every thing was lined up straight.
I would suggest even using masking tape to tape the racks down to the roof and make sure that they are exactly where you want them and even on both sides.
Now on the instructions it has a diagram of which holes to drill for different vehicles and ours is not on there. I would drill the two holes at the front of the track, the two at the end and one in the middle. Its hard to believe that these little flare nuts really hold these tracks on that well but they are rock solid!!! You can even drill all of the holes if that makes you feel more comfortable.
Heres where it gets a little scary. With the tracks taped to your roof get a metal punch and a hammer and make an indentation in the holes that you intend to drill (through the track). You really have to give it a good wack to make a mark and its a bit disheartening but its worth it in the end.
Now the instructions say to not drill through the tracks when they are on your roof, i think thats only partly true. The tracks include a large drill bit as well as the hardware but I would drill through the roof first with a much smaller bit right through the holes in the tracks. Once you have drilled the small holes through the roof then remove the tracks that are taped on and drill out the holes using the larger bit that is provided.
Dont be alarmed if you hit something under the sheet metal. I dont know exactly what it is under there, but there is another thin layer of metal in certain areas of the roof. If you get through the sheet metal and cant get the flare nut inside the hole because you hit this metal, just drill through it and then place the flare nut.
This is probably the most important part. After you drill the holes and drop in the flare nut use the provided tool to expand the flare nut by holing the large bolt with a 9/16 screwdriver (that is not provided) and turning the alen key on top. You need to Tighten the living crap out of this!!! There is nothing worse than getting to installing the screws at the end and having that thing spin with the screw because you didn't tighten it enough (trust me). After you have installed all of the flare nuts all you have to do is screw in the track.
Place a small amount of the sealant in each hole and then lay the track down and screw in the tracks to the flare nuts on the roof. Everything should line up great because you drilled the first small holes through the rack in the first place.
Then you need to buy the Thule gear that fits into the tracks and your done!! The racks look great and are completely flush with the roof. Hope this works and PM me if anybody has any questions.. Trust me If I can do it, anybody can and thanks to all the guys who gave me great advise!!
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