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[jnomura]

Well after hearing about the rubber pad 'non-fix' I went ahead to find my own solution. I don't necessarily recomend everone go out and do this as there is a risk of damaging the cross piece.

Here is what I did;
After looking at the design awhile I decided that Ford specified the Bow in the cross member incorrectly and is stuck with a ton of them (I just can't see any other reason Ford would actually tell you in the manual not to slide the cross members or paint damage may occur).
So I Removed the cross pieces and check them (upside down) and found that the center crown could be higher without increasing the total hieght of the truck by about 3/8". So I took my 12 ton pipe bender a few pieces of wood (to protect the finish) and increased the bow in the cross pieces (a lot of trial and error as they are springy) by 3/8".
I then prayed that the mounting slides would still work and they did.
Slid the cross bars back in place and now the cross members clear the roof by equal amounts all the way across (about 3/8") instead of touching in the center 2 locations. If one uses a large span and a wide support between the press and the cross member while bending, the risk of 'kinking' the cross member is reduced and a nice even bow can be made.

I noticed that the cross member has a 'T' slot on the top. I believe the intention is to attach accessories using the 'T' slot insted of the wrap around clamps.
Jim