Mounting roof rack to Leer 100XR shell

Who here has mounted a roof rack to their shell/cap? I picked up a roof rack off a 1996 Pathfinder, and when I drilled into my 100XR Leer shell I discovered an air gap, ie the roof is built like a double pane window for insulation.

I’m thinking it would make more sense to use a hole saw big enough for a socket on the inside layer so I’m not sandwiching the layers, and then cap the holes. Is this what others have done it, or did they just run the bolts through both layers and not worry about it? I feel like using epoxy to add a spacer would be ideal, but I’m not sure how well the epoxy would adhere or what to use for a spacer. Right now I have 1/4” bolts and 1” OD fender washers with nylon lock nuts, all stainless.

 

The center of the shell has a double layer of fiberglass, with a honeycomb structure in between. It appears that you drilled into that. Notice on the inside of the shell that the center of the roof appears thicker? Ideally, the holes should be drilled for the rack mounting outboard of that thick section, where there's only a single layer of fiberglass. That's where they install the optional Leer factory tracks.

Since you've already drilled the holes in the weak part of the roof, you need to do some reinforcing such as you suggest. If you tighten the bolts without spacers, you'll crush the honeycomb (which is only cardboard) and possibly crack the fiberglass.