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First, no. The window won't rattle. Like I said, it will raise well over a 1/4"more, as I have already measured it. Even if it didn't it's extremely easy to correct it by adding a 1/4" into the channel to put the gaskets where they need to be.
Second, Bolts are easy. Get longer ones for the...
I'm not seeing where you have to cut into the FG here. Explain? It should only raise the cap about 1/4 above cab (it sits flush with it, now, of course) and the back window has at least that left that it can go up. I know this because my back seal was missing, for a while until I replaced it...
It's a pic I found on the net, actually.
I am going to make some changes to it and currently dont have the equipment, so I'm taking to a few local welders. I might just say screw it though and break down and buy a good welder and pip bender and do it myself.
I like the bed of the rack. Can't say so about the choice in mounting though. I do understand the "why" of it, but just not digging it, personally. I'll be interested in seeing the final product. Perhaps it will look better to me or grow on me, heh.
Good Luck!