I was talking to one of my buddies who works at a machine shop and he said it really wouldn't be too much trouble to get some CNC machine time, especially since I can do all of the design and just transfer the model file to the machine to do the work.

So..... I'm simplifying it for the time being. I'm going to make the basic style clamp mount (shown below). I'm also going to use a square u-bolt with tri-groove nuts on top to make it a bit more theft "resistant". This isn't shown in the model....





Then, once i have my roof rack on I can take my time and really make some cool mounts for it to eliminate the crossbars.