Have tested this a wee bit but nothing scientifically! My car is a 1.2 Suzuki Swift – square profile Thule bars and footpacks, plus 2 591 racks on it…I do a daily mileage of about 20 miles – my average mpg is 51mpg. If I take the bars off, my average goes up to 52mpg.
I drove down to Leeds/York recently twice – with bars and without – I think I got about 53mpg with and 56mpg without…still not a huge difference over that distance.
That is without bikes on the roof…the bikes make a serious dent on mpg but as they are only there when needing to go somewhere it isn’t an issue.
So far, I’ve not noticed a big enough dent in my fuel consumption to bother about taking them off.