Custom rack with tonneau cover

I want to built a custom adjustable ladder rack / headache bar that uses the factory bed rail anchors while also having a hard tonneau cover that remains functional. I'm all mostly concerned about functionality (ability to haul 16ft cargo, ability to use full length of bed and fold up/remove tonneau readily, and have a somewhat dry secure storage), but at the same time I'm not crazy about the way most available ladder racks look with their vertical posts. Also need to be able to load bikes/motorcycle/atv/etc in bed. Basic question is for folks who've completed tonneau installations - how much room is available for rack brackets to mount to factory positioned rails before side rails of tonneau would be pushed in narrower than acceptable to function (ie tonneau rails mounted too narrow).
I was looking primarily at backflip mx4 or possibly the peragon tonneau, although not crazy about how the paragon folds into the bed space

My thought is to use tracked rails (either T-slot style or even something made out of unistrut) that will either lay flat along bed side decks or slightly lifted (like bedside rails), that would be anchored into factory rails under/behind tonneau cover. A headache bar will be normal positioned on these rails just behind the cab, but can be easily loosened and slid to the back of the bed to haul 15-17 ft canoes or 16 ft lumber etc. I like the idea of making a headache bar that better matches the contours of the cab instead of using most available racks that are straight vertical. I'm not going to be using the rack daily, so I'd like something that is a little more aesthetically pleasing.

I've been spoiled with my last car being a 96 4 runner that I added a roof bar above the windshield - this I could haul long lumber/canoes with and have lots of enclosed dry space in the rear, although I didn't have the utility of an open bed. This is also the newest vehicle I've ever owned and am way overthinking everything.

Apologies for the book and I appreciate any input.

 

Pace Edwards tonneau that has slots in the rails. Yakima HD Overhaul height adjustable racks.
Works great.

 

I would like the tonneau to be removable so I can use the full bed length and height (ie hauling atv/motorcycle up to the back of the cab).
I like the idea of the elevate TS rails, but they say not compatible with 23 tacoma. I'm guessing it's because the inner flange of the rail isn't long enough to reach the factory rail and the small curve of the bed rail at the tailgate end. Anyone here mount a elevate TS rail on a 3rd gen tacoma? I think it can be done, possibly using the factory tonneau bolt holes with spacers that are under the bed cap. Does anyone know how strong these factory tonneau bolt holes are/ compared to the factory bed track rails?

 

Another option

Tonneau Compatible Truck Bed Racks — KB Voodoo Fabrications

Plus they are all USA made

 

I have the Bak mx4s and the elevate rails on order. I have concerns about the width of the tonneau rails with the TS rails underneath as well, but if it does work it is closest to what I want. The Truxedo tonneau does work, or so I’m told. I like the Bak one better, but we shall see. I was thinking I like the Yakima uprights better than the Elevate ones, again if they are compatible. If this combo won’t work, I may look at a Magnum headache rack and rails. I will update this thread once I get a chance to see how things fit…

 

Yeah, I'm getting ready to order a Bak MX4 as well, but I thinking im going to make brackets to anchor a piece of extruded t-slot aluminum along the bed decks outside of the tonneau. One downside is the added height, but I don't necessarily mind the look of raised bed rails so it might not be bad. Next, the raised rail would tend to ack as a handle, but without a rear cross bar, I suspect they wouldn't feel overly secure as I think most rigidity of the racks on the market depend on the rails being tied together. This is where the low profile TS rails would be better, so I'm curious how you make out.
I'll post updates as things materialize.

 

Finally, all of the parts are in my garage. Unfortunately, the truck is fully loaded for a road trip over the next couple days. I expect to get back to this project on Thursday, I will post pictures as I put this together. Tonneau will be installed for sure, TS rails as well if they fit. Went with 6’ rails, so a bit of trimming was required. It shouldn’t show once everything is assembled tho…

 

So after some time being sucked into the endless hole that is the internet, I'm leaning toward using the rhino rails with rivnuts into the bed rail caps that I've discovered a handful of others using. This should give me the most versatility of adding what I want and won't affect tonneau cover mounting (ie having to worry about bolt in brackets lifting or shifting the tonneau rails too narrow. I'm leaning toward a revolving rollup style hard tonneau to still allow rear view line of sight when opened.
Only downside is drilling into the bed cap, but I'm only hesitant on that because the truck so new, so I need to get over that...

 

I would like to see these "elevated rails." Very curious what you have in store for the backflip and racks

 

Look at billie bars too.

 

Kind of a shame I trimmed the Elevate rails ☹️.

So, a quick follow up, the RevolverX4S (which is an awesome looking cover) will not work with the Elevate rails. The S-clips that attach the tonneau rails to the truck do not have much clearance. I could not align them properly with the Elevate rails in place. I guess I’ll be looking into the Rhino Rails option…

 

Cree River, was there not enough vertical slop in the aluminum rail brackets anchoring holes to get fasteners in? If this is the case, any local machine shop or person with a mill (or patience with a dremmel or something) could slot those bracket holes out. My concern was if the elevate rails shifted the tonneau rails inward to prevent proper function of the tonneau. Note that there are also a bunch of toyota oe tonneau cover tapped bolt holes just under the plastic bed rail cap on the inside of the bed (Pic below) that you could anchor the elevate rail into, but that would require some light trimming of the plastic cap and some small spacers, but would probably make a more rigid anchor point than going down further to the factory tie down rails.
For my truck I was originally trying to get a bolt on system with no drilling or cutting of bed deck caps, but the more options I look at, I'm liking the rhino rails anchored in to the bed deck for what I ultimately want for functionality.

 

So, when I had my Jeep Gladiator, my revolver x4s side rails had built in tracks. I’m wondering why they don’t update the Tacoma rails to include a track, or can the Gladiator side rails be used for a Tacoma?

 

As it sits, there is very limited space witdth-wise. I would estimate approximately 1/8” both sides combined. It is possible that the plastic caps will shift a bit wider with pressure, but that might cause it’s own issues. I like the tonneau, so I will be keeping it and will continue to search for a good rail option.

 

It looks like these guys were able to make the elevate work. https://www.youtube.com/watch?v=MktaZd8Sa3A was there a large difference with X4s? Looking to get a rail setup myself as well without needing to purchase something like a retrax.

 

Different cover. Mine is the Revolver. I suspect the width tolerances are different with that one. That said, I wouldn’t say it is impossible, just that I couldn’t get it to work. I’m pretty much committed to the idea of bolting a rail at this point. However, it will be a bit over 3 months until I actually see my truck again, things could change it that time…

 

no one has the tracks available.

 

This will be my salvation....

 

What cover do you have?

 

if you can find them...