Chad,

I built a carrier that works with a Thule rack. 2 2x4's are glued together to make a cradle that is 3" by 3 1/2". The appropriate hull curve (determined with a flexible ruler and a cardboard template) was cut on each cradle. On top of this cut curve was glued pipe foam insulation. This foam was finally covered with water repellent fabric and secured with with spray adhedsive and brass hardware. A dado was cut on the underside of the cradle that fit over the rack bar. Hardwood brackets were made to fit the underside of the rack bar. Stainless steel bolts go through these brackets and into inserts that are threaded into the underside of the cradle. The kayak is held in place with a simple racket web tie down. To make it easy to use the racket itself if mounted on one end (near the outside of the car) and the webbing is attached to the other end of of the cradle. THis may not be the easiest cradle to build but it supports the kayak extremely well and is very quick to attach/release from the car top.

Hopes this gives you some ideas you can use.

Randy

> Does any one have any good ideas about building kayak saddles
> for the top of my car?

> I have been getting by with foam padded Yakima bars. They have
> been fine for short trips but I would like some thing a little more
> secure for longer trips.

> I could buy the Yakima ones, but for two boats that is $160-
> $220. I could almost build another boat for $200.

> Does anyone have any cheaper suggestions?

> All thoughts are appreciated.

> CHad