Originally Posted by E-350
Sounds like I don‘t really get around drilling a hole in the roof, right?
And then distribute from there to wherever needed on the rackAttachment 45113
I would not be that concerned about drilling holes in the roof. For example, the biggest holes would probably be for solar panels and then you would want to use something like this. Personally, I have only installed a single large 360-watt residential panel and so there is only one wire pair required.
Alternatively, I have bought 1/2" thick ABS plastic scraps and use that to make a foot for mounting points.
They come in different colors. I drill a hole for a stainless bolt with a nylock nut, and then make an oversized counter sink from the bottom (e.g. twice the bolt size). This then provides a nice cavity to fill with silicone or your favorite sealant and I have had no leaks doing this.
If you have to run wires along the rack, I would be tempted to put in a set of conduit runs that you just weld to the rack for the wires. I spaced mine out a little so I could slip shrink tubing over the end of the conduit to minimize water in the conduits. The attached picture is wiring on a motorcycle carrier. Tie straps take a beating, especially in hat Az weather so this is more robust all around.
Also if you are going to do a lot of wiring to a rack I would put a connector on it or make some providing so you can pull the rack down easy without having to but too many or your connection.