Thule 500 Xsporter Pro Multi Height Aluminum Truck Rack Out of Box Review and Assembly Photos

31st Oct 2012

The Thule 500 Xsporter Pro Multi-Height Aluminum Truck is a heavy duty, aerodynamic and versatile load carrier.  This truck rack is totally unique in design, offering 32 height positions that are easily adjusted using easy to use turn knobs to loosen the upright and a smooth action to raise and lower the bars.

The complete truck rack is carefully packed into the most compact box possible measuring 73 x 14 x 4.5 inches with a total weight of 65.5 pounds.  The complete truck rack itself weighs only 58 pounds, which is remarkably light for truck rack with 450 pound carrying capacity.

Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-1-box-dimensions.jpg

Before assembling a rack it is very important to open the box, pull out the manual and review the parts.  Working in a clean, well lit area is essential to avoid misplacing parts during assembly.  This rack requires approximately one and a half hours to assemble and install.

Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/ 

thule-500-xsporter-pro-assembly-2-opened-box.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-3-out-of-box.jpg

The first stem of assembly is to attach the load bar saddle to the upright.  The saddle can only be attached to one specific end of the upright and it doesn't matter what direction it is placed on the end of the upright so it's very straightforward.  The 7/32 inch hex key is included, and the bolts are treated with a thread prep which helps to prevent the bolts from ever vibrating loose.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-4-first-step.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-5-uprights.jpg

Next is sliding upright into the base assembly, the photo below shows how the upright is held by the base QuickDial using a square-head bolt which slides into the numbered Gear Rack slot.  This is a simple and solid means to secure the bar and allow for easy 32 height adjustments.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-6-second-step.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-7-bases-with-uprights.jpg

A total of four Thule lock cylinders are included with the rack system.  The photo below show one cylinder being use in one of the upright's end cap.  This locked on cap will not allow the upright from sliding past the base assembly.  The overall locking strategy is to lock the two driver side uprights, thereby preventing removal of the complete upright/load bar assembly.  An additional two lock cylinders are included to lock the based to the bed rail of the truck, see below for more details on that.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-8-upright-lock.jpg

This is step four, installing the load bar fasteners to the load bar saddles, then sliding the bar onto the saddle.  At this step the bolts should remain loose for final adjustment on the truck.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-9-bar-fasterners.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-10-bar-attachment.jpg

There are a total of eight bed rail clamps.  There are two t-slide lock adapters shown being attached in the photo below, these are used for two of the driver side bed rail clamps, one for each base assembly.  The 5/16 inch hex key needed to fasten the t-slide lock adapters is not included.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-11-clamps.jpg

Below is one of the Thule lock cylinders being installed into the clamp lock housings, this housing will prevent access to the bed rail fastening bolt.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-12-clamp-lock.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-13-clamp-lock.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-14-clamp-lock.jpg

The rubber WindDiffuser cross bar strip is pressed into the load bar's t-slot to disturb airflow over the bar which effectively reduces wind noise.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-15-winddiffuser.jpg

The load bar end caps can now be installed using the hex head bolt which requires a 5mm hex key to fasten.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-16-end-cap.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-17-end-cap.jpg

Vehicles with bed liners that ubstruct access to the bed rail underside could require modifications.  An adapter kit for the Toyota Tacoma is required to install the Xsporter Pro and many lower positions are not available due to the rear wheel well at the front of the bed as well as the angled bed liner towards the rear of the bed.  Always check the Thule Fit Guide for complete fitment information.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-18-complete.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-19-bases.jpg

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-20-clamps.jpg

Rubber shims are included to provide protection between the bottom of the base and the truck rail finish.  These shims are flat on the bottom and curved on the top to match the curve on the underside of the bases.  This curved interface helps to customize the fit and permit the best angle for the uprights.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-21-bases.jpg

The Thule 500 Xsporter Pro is designed for strength and aerodynamics, the load bar used AirTrip and WindDiffuser technology, both features have been show to reduce wind noise and wind drag.

 Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/

thule-500-xsporter-pro-assembly-22-load-bar.jpg

Get 10% off, FREE Shipping and no tax outside Texas, easy ordering:
%%GLOBAL_ShopPath%%/thule-500-xsporter-pro-multi-height-aluminum-truck-rack/