Sherpa Load Bars Explained: Lightweight Carrying Solutions

A full platform roof rack is one of the most capable upgrades you can put on a truck or SUV, but it is not always the right tool for the job. Some people don't need full coverage and a rack that acts as a platform across the entire roof. If that is you maybe load bars suit your needs. If you primarily carry one or two types of gear and want to keep weight down and wind noise low, a pair of Sherpa load bars can accomplish everything you need without the bulk of a full rack. Sherpa's load bar systems are built to the same standards as their famous Sherpa roof racks, just in a lighter, leaner package.

This guide covers Sherpa load bar systems in detail including the Roof Track Load Bar System for vehicles with factory roof tracks, and the SmartCap Load Bar System for trucks running an RSI SmartCap. You'll find everything you need to know about sizing, load capacity, compatible accessories and how load bars compare to a full rack setup. You might also browse the full Sherpa Load Bars collection at Truck Brigade to see if there is a precise version for your vehicle.

Why Load Bars?

Not every adventure requires a full platform rack. Maybe you hit the road once a month for kayaking and need something reliable to carry your kayak and paddles. Maybe you're just needing something simply to mount a couple pairs of skis. Load bars do both of those things great and more giving you two solid crossbars that mount to your factory roof tracks with no drilling, no major weight penalty and no complicated installation.

Sherpa's load bars are built with the same aluminum extrusion crossbar profile used across their PEAK Series and SPORT Series rack lineup. That means the T-channel slots running along each bar are fully compatible with drop-in T-nuts and the entire Sherpa accessory ecosystem. You get maximum flexibility in a minimalist package.

Roof Track Load Bar System

The Sherpa Roof Track Load Bar System is a pair (except for the 2024+ Land Cruiser 250 which comes with three) of extruded aluminum crossbars that bolt directly to your vehicle's factory roof tracks. No drilling required and no modification to your roof. Simply remove the factory track end caps, slide in the mounting feet and tighten down with the provided hardware. The system is designed to be straightforward from start to finish. For a broader look at the complete Sherpa lineup including full platform racks, see our Sherpa Equipment Company overview.

Sizes Available

The Roof Track Load Bar System Universal Load Bars comes in four lengths: 43 inches, 48 inches, 55 inches and 60 inches. Vehicle specific load bar kits are also available for: 2024+ 4th gen Tacoma (double cab), 2024+ Land Cruiser 250/Lexus GX550, 1996-2002 Toyota 4Runner, and 2005-2023 3rd gen Tacoma (double cab). Each vehicle specific version is designed to span the factory track width of the vehicle platform. Mid-size trucks and SUVs typically use the 48-inch bar, while larger or wider platforms step up to 55 or 60 inches. We cover sizing in detail in the Choosing the Right Size section below.

Load Capacity

Sherpa's Roof Track Load Bar System is rated at 200 lbs dynamic and 500 lbs static. That means the carrying capacity is more than enough for a rooftop tent, a pair of bikes, two kayaks or a loaded cargo box. As with any roof-mounted system, always distribute weight evenly across both bars and secure your load properly before hitting the road.

T-Channel Accessory Slots

Each crossbar features multiple 1/4-inch T-channel slots running the full length of the bar. Drop-in T-nuts slide into these slots, letting you position accessory mounts anywhere along the bar without drilling. This is the same mounting interface used on Sherpa's full PEAK and SPORT Series racks, so any accessory designed for Sherpa crossbars will work on the load bars as well. Note given the distance of the load bars some accessories will not work properly because the munting holes are too narrow. For a full breakdown of compatible accessories, read our Sherpa Roof Rack Accessories guide.

SmartCap Load Bar System

If you're running an RSI SmartCap on your truck, Sherpa built a dedicated load bar system specifically for that application. The SmartCap Load Bar System works with the RSI track system built into the SmartCap's frame rails, delivering a secure, flush mount that integrates cleanly with the cap's design. It's a natural pairing with the Sherpa Crow's Nest Topper Rack, which also has a version designed for truck cap applications.

What's Included

The SmartCap Load Bar System comes as a complete kit: 2 or 3 crossbars, 4 or 6 contour adjustable mounts (universal kit also comes with flat adjustable mounts) 4 or 6 endcaps, and all the necessary hardware. Everything you need is in the box. on the SmartCap version you will need to use SmartCap track nuts which should have came stock with the RSI roof tracks.

Load Capacity

The SmartCap system is rated at 200 lbs dynamic and 500 lbs static. This is a significant step up from most load bar systems on the market. That makes it well-suited for heavier loads like rooftop tents, large cargo boxes or multiple bikes. The higher static rating reflects the strength and quality of Sherpa's design and engineering.

What You Can Carry

Sherpa load bars are versatile enough for a wide range of cargo setups. The extruded T-channel crossbars work with most aftermarket accessory brands as well as Sherpa's own accessories, giving you flexibility to build the exact carrying solution you need.

Bikes

Bike carriers are one of the most popular uses for Sherpa load bars. Fork-mount and wheel-mount bike racks attach directly to the T-channel slots using drop-in T-nuts. Our customers have carried two full-size mountain bikes without any flex or movement from the bars, even on longer highway runs. The adjustable height lets you position the bars to keep the bikes stable and aerodynamic.

Kayaks and Paddleboards

Foam saddle kayak carriers and J-cradles both work well on Sherpa load bars. The T-channel slots let you space the mounts for your specific kayak length. Multiple users have carried tandems and recreational kayaks on 55 and 60-inch bars for multi-day paddling trips, reporting solid stability at highway speeds. Surfboard carriers and paddleboard saddles work the same way.

Cargo Boxes

Cargo boxes from brands like Thule, Yakima and and Roam mount directly to the T-channel slots. Owners frequently use load bars with cargo boxes for ski and snowboard trips, hauling camping gear, and keeping overflow luggage off the interior seats. For most cargo boxes, the 48-inch bars are sufficient, but longer boxes benefit from the 55 or 60-inch options to ensure a secure fit.

Rooftop Tents

Yes, you can mount a rooftop tent on load bars, but we would generally recommend a full-size roof rack that will better support the rooftop tent. With 500 lbs of total capacity, most softshell and lighter hardshell RTTs are within range. 

Solar Panels, Ladders and More

Users have also mounted solar panels, fiberglass ladders, conduit and pipe for trade work, and extension ladders on Sherpa load bars. The clean T-channel interface means almost anything with a standard clamp or universal mounting foot will secure properly. If you're building a work truck setup and don't need a full rack, load bars let you add the carrying capacity you need without going all-in on a platform rack.

Choosing the Right Size (RH Here)

If you are not ordering a vehicle-specific option, picking the right bar length is the most important decision you'll make with Sherpa load bars. Go too short and the bars may not span the full track width of your vehicle. Go too long and the bars can overhang past the tracks and roof line, which can reduce stability and potentially come in contact with overhangs and other items.

48-Inch Bars

The 48-inch bar is the go-to for most mid-size trucks and compact SUVs.  It's the most common size in our Sherpa Load Bars collection for a reason as it covers the widest range of popular vehicles including some overland trailers.

55-Inch Bars

The 55-inch bar is well suited for vehicles with wider factory tracks. This  includes certain topper applications and mid-size trucks with longer cabs. If you're running a camper topper on a mid-size platform, the 55-inch bar often provides the best fit and the most accessory mounting real estate.

60-Inch Bars

The 60-inch bar is designed for full-size trucks and larger SUVs with wider factory roof tracks. If you're running a full-size truck, measure your track spacing before ordering to confirm the 60-inch bar is the right match.

How to Measure

Before ordering, measure the center-to-center distance between your factory roof tracks, then add a few inches on each side for accessory mounting clearance. Sherpa provides fitment guidance on each product page. When in doubt, contact our team at Truck Brigade or compare your track width against the specs for each size. Getting the right measurement up front saves time and prevents the need for a return.

Load Bars vs Full Roof Rack

The most common question we hear: should I get load bars or a full rack? The honest answer is that it depends entirely on how you use your vehicle. Both are excellent solutions, but they solve different problems. Our Sherpa Racks Explained guide covers the full spectrum of rack options in depth, but here's how load bars specifically fit into the picture.

When Load Bars Make More Sense

• You primarily carry one type of gear (bikes, kayaks, a cargo box) and don't need a full platform
• Fuel economy and wind noise are priorities. Load bars generally have less wind drag
• You want a simpler installation and a cleaner look when nothing is mounted
• Your roof rack use is occasional rather than full-time
• You're on a tighter budget but still want Sherpa-quality construction
• You don't intend to mount various accessories. Since the load bars are further apart usually, some accessories will not work that require multiple load bars to mount.

When a Full Rack Makes More Sense

• You carry multiple types of gear simultaneously (tent + bikes + accessory panels)
• You want to mount lights, antennas, traction boards and other accessories permanently
• You need the full side-plate structure for built-in handles and tie-down points
• You're building a long-term overlanding rig where the rack is a permanent fixture

Weight savings are real with load bars. A Sherpa PEAK Series roof rack like the Crestone for the 5th Gen 4Runner weighs around 50 lbs. The Roof Track Load Bar System is dramatically lighter. In fact, the SmartCap system checks in at just 8 lbs for the entire kit. If you're trying to keep roof weight minimal, especially on a truck with a topper where you're already adding mass, load bars are a clear winner. Browse the Sherpa Equipment collection to compare options side by side.

Installation

One of the best things about Sherpa load bars is how easy they are to install. There is no drilling, no permanent modification to your vehicle, and no specialized tools required. Both systems are designed as bolt-on solutions that work with existing factory hardware.

Roof Track System Installation

The Roof Track Load Bar System mounts to the factory T-slot track channels running along your vehicle's roofline or camper. The provided hardware slide directly into these tracks and attach to the included Sherpa mounting feet.  The process takes most owners less than an hour with basic hand tools from start to finish.

1. Remove factory track end caps (if applicable) to access the roof track channel
2. Slide mounting feet into the factory track from the end
3. Position feet at the correct spacing for your bar length
   
4. Torque all hardware to the specified settings
5. Install drop-in T-nuts into bar channels and attach accessories

SmartCap System Installation

The SmartCap Load Bar System installs into the RSI SmartCap's built-in rail system. You'll need SmartCap-specific track nuts (not included) to secure the mounts. Once the track nuts are in place, the mounts bolt on and the crossbars drop into position. Endcaps install last for a clean, finished look. For more on topper rack systems and cap-compatible setups, read our Sherpa Topper Rack guide.

Compatible Accessories

Sherpa load bars use the same extruded T-channel crossbar profile as the PEAK Series and Sport Series rack crossbars, which most of Sherpa accessories designed for crossbar mounting will work directly on your load bars. Drop-in T-nuts are the key and slide into the channel and allow you to position any accessory mount anywhere along the bar. Note that some accessories will not work with the Sherpa Load bars depending on the distance between the load bars.

Popular accessory pairings with Sherpa load bars include traction board mounts, Rotopax mounts, and HiLift brackets on load bars if your vehicle calls for it. The full accessory catalog is detailed in our Sherpa Roof Rack Accessories guide. Browse the Sherpa Accessories collection for the complete selection.

Frequently Asked Questions

What is the weight capacity of Sherpa load bars?

The Roof Track Load Bar System is rated at 200 lbs dynamic and 500 lbs statis.

Do Sherpa load bars require drilling?

No. Sherpa load bars are drill-free. The Roof Track system slides into your factory roof track channels. The SmartCap system mounts into the RSI SmartCap's built-in track rails. No holes are made in your vehicle.

Can I use Sherpa accessories with load bars?

Yes. Sherpa load bars use the same extruded T-channel profile as PEAK Series rack crossbars. Some accessories will work with Sherpa load bars, but not all are guaranteed to work due to the distance between the load bars. See our Sherpa Roof Rack Accessories guide for the full list.

Do Sherpa load bars work with a rooftop tent?

Yes, as long as your tent's weight falls within the load bar capacity. Most softshell rooftop tents and lighter hardshell models are compatible. Always confirm your tent's minimum roof bar weight rating against the Sherpa bar specs before purchasing.

What vehicles do Sherpa load bars fit?

The Roof Track Load Bar System fits any vehicle with factory T-slot roof tracks. Additionally, there are Sherpa vehicle-specific kits which are available for the 2nd, 3rd, and 4th gen Tacoma, 3rd gen 4Runner, and 2024+ Land Cruiser 250. There are also universal models available. The 48-inch size suits most mid-size trucks and SUVs, the 55-inch covers wider platforms and certain toppers, and the 60-inch fits full-size trucks. The SmartCap Load Bar System fits any truck running an RSI SmartCap. Confirm fitment for your specific vehicle on the product page or contact our team.

How does the Sherpa load bar system compare to a full platform rack?

Load bars are lighter, lower-profile and less expensive than a full PEAK Series or SPORT Series rack. They're ideal for single-purpose or occasional use. A full rack provides a larger platform, more accessory mounting points, integrated side plates and higher overall load capacity. See our Sherpa Racks Explained guide for a full comparison of the entire lineup.