After using painters tape on every place I could think of and driving around the block several thousand times to test, I have found was appears to work. Zero noise up to 50, then slight (but normal) roof rack noise thereafter. At 75 the tape came off but was quiet up to that point. No more whistle or sound at 25 mph and above!
All I did was tape the gaps on the rubber seal across both bars. Instant change. Obviously not a permanent solution, but at least I can work from here and find a way to seal that top, doesn't look bad, and will last. I read on another blog that someone used vinyl to cover silver racks, wondering if 'wrapping' would be the best method. First I am going to remove the rubber seals once more and really stretch/bend them. Reinsert and see if that just solves it. The racks have also not sat in the direct sun for long to loosen up the rubber.
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