Does anyone know if it's possible to order a FEH with the no boundaries rack? I know it's not a 'stock' option, but I wasn't sure how custom Ford would allow you to go from the factory.

The No Boundaries rack is available on the non-Hybrid version of the Escape only. You may be able to add it to the Hybrid - but there is probably a reason that they don't offer it.

Putting a bigger rack on it will probably make a noticable mpg difference. I know some Prius owners that lost 4mpg putting a kayak rack on top of their car (with no kayak on it).