Objective

I managed to pick up these Thule roof bike racks and need to modify them to attach to my aero bars. The original rack was used with square bars.

Replacing the Locks

Managed to get some replacement locks from amazon for about $10 so we might as well replace them.

I ended up drilling them out (a lot) and then pulling/pushing them out after a slight quarter turn clockwise(I think).

New Lock and Keys: https://www.amazon.ca/dp/B0CC24DRJQ?ref=ppx_yo2ov_dt_b_fed_asin_title

Modifying for Aero Bars

My Subaru bars have a width of about 2 1/2" (63.5mm).

Attempt #1

I bought the following kit to update attach the Thule rack to the bars.

https://www.amazon.ca/dp/B0BMBCQFD3?ref=ppx_yo2ov_dt_b_fed_asin_title

Universal galvanised steel U-bolts, inner width 85mm/3.34in, outer width 90mm/3.54in, which can hold up the luggage rack about 40mm/1.57 inches thick.

Inside: 3 1/4" Outside: 4"

Threaded Rod: M8

So, I ended up notching the metal plates such that the u-bolts go around the Thule bottom plate. This is fine if you add the plastic top bar. Initially, I thought this kit came with a metal top plate but it turned out this piece that I thought was metal was rubber....