Van roof rail spacer for Unistrut

thingiverse

3D printable spacers to go between a vehicle roof and a Unistrut rail to keep the rail clear of the roof, and with variable height spacers you can compensate for curves in the roof. There is a channel at the bottom to allow a bead of Sikaflex or similar sealant to make a good watertight seal between the roof and the spacer. You will also need to put a bead of sealant around the bolt when tightening it down. It's important to high quality stainless steel M8 bolts and washers. I used M8 hex bolts, through the factory made holes in the roof of a 2017 VW Crafter LWB into M8 Rivnuts - but you should be able to adapt it to most vehicles. I used 41x21 lightweight (1.5mm thick) Unistrut, but it will work with most strut. I've provided spacers of 3mm, 5mm, 10mm, 15mm and 20mm, but also included the model file (.STL) which was created in TinkerCAD so you can create spacers of different heights if you wish. When 3D printing I used PLA with 50% infill (for strength) and with course setting (.4mm layers). If these work for you, it may be worth getting a printing service to print them in something that is more UV resistant.