B6 Passat rack to fit on B6/B7 A4/S4

**darkstar** · 08-17-2010 08:14 PM

Hey guys doing my own DIY for the B6 passat VW rack to Fit on our cars

I got my rack from genuinevwaudiparts.com Rack *here* P/N 3C0071126

Tools needed
- rack tool (comes with rack has allen and special socket for the rack bolts)
- square
- punch
- hammer
- scoring tool ( i used tungsten from my tig)
- some sort of saw (hack saw should work fine)
- flat heat screw driver
- drill or drill press
-measuring instrument (calipers, tape measure, ruler whatever you have!)

optional
- extra set of allen's

I used the measurements that dackler posted PDF file here Thanks for those makes things a lot easier! they were dead on!

Ok so first thing is first i always worked from the right side of the racks that way i could retain the factor stickers on the bottoms telling you which front and rear.

1: Start by first taking off the side mounts that clamp inside of the doors using the tool supplied with the rack.

2: Then remove the small plastic plugs that are hiding 2 (5MM) allen bolts remove both bolts.

3: Then you are able to remove the inner supporting foot and cover, then side out the steel sliding block. the side of the rack should be fully disassembled.

4: after the rack is all disassembled on the right side then its time to start making some holes! i used dackler measurements they are listed above.

now for the front rack the holes need to be moved forward 55.0mm rear rack needs to be moved inwards 88.0mm these steps can be used for both just makes sure you use the correct measurements on the correct rack.

Now what i did was i used my square and lined it up with the factory slotted hole and covered up the radius part (just so that the slotted hole no longer had and radius showing) with the square then scored it. then repeated the same from the next hole.

5: Next i used my calipers and set them to my measurements i need (front 55.0mm)(rear 88.0mm) then i used my square and measured from my original line that i scored moved inward on the rack till i moved the correct distance then scored the rack then repeated the same step for the next hole.

6: now at this point you should almost be ready to drill some holes but before i did i went and test fit the rack on my car i liked up the rack with the holes in the door and seat the right side support foot under lining it up with the gutters where it sits on the car then used a marker to mark the front hole to make sure i am where i need to be with my measurements

7: After you make sure you measurements are on target you need to find the center of the rack so you can use a punch to get you a nice punch to get you drill bit started the rack is 2.25" wide so the center would be 1/2 of that which is 1.125" using you square measure it out and score it on each spot where the new holes will be.

**darkstar** · 08-17-2010 08:16 PM

8: Now using your punch line up your makes you made and punch a started spot for the drill.

9: Now its time to drill some holes! i started off with a small pilot bit like 1/16 then step up to a 1/4" bit

10: now after i drilled them out i went ahead and went and test fitting again to make sure the holes were correct and i didn't have to slot them at all to get a good fitment. so slide the sliding block back in and using the 2 (5mm) allen bolts fit the support foot back on to the rack and make sure that you fit is good between the gutters.

*note*you may need to use a screw driver to get the sliding black in place

**note if you do not have good fitment you may have to slot the holes with a dremel or die grinder to get the fit you need you can always try adjusting from the unmodified side.

WE ARE GETTING CLOSE!

11: Now take the support leg off and remove sliding block, then using the measuring device i used my caliper, measure from the end to the amount you moved the holes on the rack (front 55.0mm) (rear 88.00mm)

12: Now we are ready to cut! i used a bandsaw you can use whatever you life or have access to. i clamped my piece very carefully and confirmed my amount i wanted to remove, then cut!

13: after i cut my piece i went ahead and used a metal file and cleaned up my cut.

14: Now it is time to start putting things back together! start with sliding in the slide block, then put on the support foot cover, then put on the support foot and secure with 2 (5mm) allen bolts.**note** it was easier to put the deep of the 2 bolts on the racks side, then install 2 small plugs to cover bolt holes, after that then put on outer tensioning clamp.

**note make sure to leave the tensioning clamps pretty loose to help fitting the rack.

15: installation! at last! ok so now open all 4 doors find the alignment marks inside the door jamb. Lining the correct front and rear backs on the car making sure you have the left on the driver side of the car. tighten down rack according to manufactures instructions.

**darkstar** · 08-17-2010 08:17 PM

16: stalling rubber strips with the rack installed and molded caps closed push down the rubber strips in the channel then cut when you get to the other side.

Now enjoy your 56 dollar rack!!!!!!

the end!

**NetLogic** · 08-17-2010 08:20 PM

Thanks for the post and taking the time to do the DIY. A+

**darkstar** · 08-17-2010 09:17 PM

Thanks! i hope it helps those people out that want to do it.. pretty much step by step!

**gray6spd** · 08-17-2010 09:29 PM

Sweet DIY! My bars are at my cousin's machine shop getting new slots in the morning!

**darkstar** · 08-18-2010 12:56 AM

Good times dude! its such a good deal you cant pass it up! pretty much 300 bucks off.. i like how this rack is a little lower profile too!

**mister_tu** · 08-18-2010 04:52 AM

Good stuff...now put a fairing on it!

**dackler** · 08-18-2010 04:59 AM

Awesome writeup! I'm glad the measurements worked out for ya!

**bmags88** · 08-18-2010 06:13 AM

Awesome writeup!!!! This couldn't have come at a better time. I just got my Passat rack in the mail yesterday from ECS and was planning on doing this mod this weekend. Great job!

**n7plus1** · 08-18-2010 07:00 AM

part number?

**NetLogic** · 08-18-2010 07:11 AM

Originally Posted by n7plus1

part number?

3C0071126

**pondside36** · 08-18-2010 07:38 AM

Good stuff, until I saw the price I was thinnk why all that work for something that looks just like the Audi one's, nice write up.

**ECS Tuning-Audi** · 08-18-2010 07:38 AM

Fantastic DIY, great photos and your car - well you car is also fantastic looking!

**mister_tu** · 08-18-2010 08:12 AM

darkstar, would you be willing to do this mod for a fee?

**n7plus1** · 08-18-2010 10:01 AM

i want to do this but need a part number to search.

**dackler** · 08-18-2010 10:34 AM

Originally Posted by n7plus1

i want to do this but need a part number to search.

Check post #12 above

**n7plus1** · 08-18-2010 01:11 PM

mustve missed that thank you.

**J3RR3L** · 08-18-2010 02:33 PM

i like the way it clamps to the roof. looks like a better than my yakima mounts

**darkstar** · 08-18-2010 05:19 PM

Thanks guys i think it took longer to do the write up then to mod the rack! i hope it comes in handy for those who are wanting to do this... i have used so many DIY from AZ and A4 mods to pretty much do anything on my car! just wanted to pass on the love!

**JustinCase** · 08-18-2010 09:50 PM

I ordered one from GAP and they said its going to be 2 weeks until they have it in stock just so everyone knows.

**darkstar** · 08-18-2010 10:42 PM

good looking out! i took about a week to receive mine! the rack actually had been damaged during shipping Bill over there took care of me and shipped out the replacement part ASAP!

**1.8Turbo4me!** · 08-18-2010 10:46 PM

nicely done....and very nice car!

**alpinestar180** · 08-18-2010 11:47 PM

god i wish i had all those tools and stuff. would have made it a lot easier to do mine. probably took me 3 hours the first time because i had a hack saw blade (no handle) and a cordless drill and a sharpie.

**n7plus1** · 08-19-2010 05:06 AM

Originally Posted by JustinCase

I ordered one from GAP and they said its going to be 2 weeks until they have it in stock just so everyone knows.

coo, thanks justin.

**n7plus1** · 08-19-2010 05:07 AM

any reason you didnt do slots instead of just holes?

**naiku** · 08-19-2010 05:10 AM

Great job, I was all excited about this, then realized it would not work on my Avant! nonetheless a great DIY and way to save a large amount of money.

**bmags88** · 08-19-2010 05:22 AM

ECS has them in stock. I got mine in less than a week for $90 shipped.

http://www.ecstuning.com/Volkswagen-...Rack/ES342630/

**Homer** · 08-19-2010 07:53 AM

Cross post from B7 forum on my part, but who makes the factory rack system? Just bought the rack from GAP, but I'm looking to see if attachments can be bought elsewhere.

**bmags88** · 08-19-2010 10:09 AM

The cross bars are similiar to the Thule Aero bars so anything with those mounts will work. ECS actually have some cool bike carriers that come in different colors.

**boostedAvant** · 08-19-2010 10:20 AM

Wow... this may have to happen when I make my rack for the Avant... Will it attach to the Avant you think? I might have to get creative.

**darkstar** · 08-19-2010 12:45 PM

Originally Posted by alpinestar180

god i wish i had all those tools and stuff. would have made it a lot easier to do mine. probably took me 3 hours the first time because i had a hack saw blade (no handle) and a cordless drill and a sharpie.

Lol well as long as you got it done that all that matters!

Originally Posted by n7plus1

any reason you didnt do slots instead of just holes?

The measurements were spot on i didnt see a need to slot the holes.. if the fit wasn't very good i would have.

Originally Posted by boostedAvant

Wow... this may have to happen when I make my rack for the Avant... Will it attach to the Avant you think? I might have to get creative.

That is a good question. i would think maybe the rack system would attach to the factory rails instead of in the doors. if you have the mounts inside the doors why not try it!

**n7plus1** · 08-19-2010 03:04 PM

Originally Posted by bmags88

The cross bars are similiar to the Thule Aero bars so anything with those mounts will work. ECS actually have some cool bike carriers that come in different colors.

yeah, the rocky mounts...my roomie got one for his b5.5 passat...pretty good quality.

**ECS Tuning-Audi** · 08-20-2010 07:33 AM

Originally Posted by n7plus1

yeah, the rocky mounts...my roomie got one for his b5.5 passat...pretty good quality.

We do indeed. They are colorfully powder coated so you can make your rack as stand out as you'd like - or as subtle as you like. Really, for the price, quality and function - our Rockymounts can't be beat. They were designed for VW Audi and BMW base bars specifically so fitment is superb. For anyone interested they are found here.

**Homer** · 08-20-2010 08:06 AM

Originally Posted by Chris@ECSTuning

We do indeed. They are colorfully powder coated so you can make your rack as stand out as you'd like - or as subtle as you like. Really, for the price, quality and function - our Rockymounts can't be beat. They were designed for VW Audi and BMW base bars specifically so fitment is superb. For anyone interested they are found here.

I see a few pictures on your site that seem to use the "Euro PitchFork Standard Plate/Custom Rear Mount Kit".

Is that included or extra?

**ECS Tuning-Audi** · 08-20-2010 08:47 AM

Originally Posted by Homer

I see a few pictures on your site that seem to use the "Euro PitchFork Standard Plate/Custom Rear Mount Kit".
Is that included or extra?

I realize it isn't photo'd directly but yes, they are included by default with all our Rockymount kits.

**mda0428** · 10-08-2010 06:26 PM

any idea why the rack is now $250 on genuine?

**ECS Tuning-Audi** · 10-11-2010 05:26 AM

Originally Posted by mda0428

any idea why the rack is now $250 on genuine?

Hard to say - but I suspect it is because this item is no longer being manufactured and quantities are now limited to what are available. ECS now offers two options:

One: B6 Passat rack that will be ready to be modified to fit the B6/7 for $74.96.

Two: ECS-assembled B6/B7 roof rack that is ready to mount on your car for $149.95.

...and we have a BUNCH of these on hand!