Thule xsporter - Cutting for 1st gen

I picked up a Thule Xsport Pro 500xt over the winter. The expectations where to keep it below the windows for most of the time to load MTN bikes easily then use it's adjustability to raise it for the occasional boat trip. Quickly learned that 1st gen beds are too shallow. Stock bar length, the lowest position was mid window. The wheel wells also make front bars location limited, rack has to set so far forward that the bike racks can't open, or so far back that the bike wheels stick out over the back. Conclusion was it needed to be cut down somehow.

After reading a few forums there were lots of people asking but wasn't much information on how to do it. Well the weathers warming so I started to tinker and figured out a way. It's not too complicated.

If you cut it below the "27" notch, at full extension the cross bar will set about 2 inch above the roof. It also leaves enough to use the cut off as a stubby upright that will clear the wheel wells.

All you need to do is cut as straight as possible. Once cut, the top cap is held to the rail by 2 x 3/8"-16x1.5 flat head screws. To use the stubby all you do is tap these threads into the stubby and swop as needed. The holes are already there, you just need to tap. The locks will still work on both long and stubby rails with no extra work. You can also just tap the bottom holes of the rails and use a bolt and washer as a ghetto locks, in fact it likely stronger then the key locks.

This isn't as easy to go from below window to above roof as advertised but it does still give you the option of both with one rack.

I also didn't like the stock flush black end caps so I made my own. It's 3D printer TPU. They are soft rubber so when I bang into them it hurts less and are more visible. I plan on putting that STL online as a free download someplace. I will share that when I get around to it.

Here are some visuals....

Full height pics are pre cutting.