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Old 10-04-2012, 08:08 AM
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Roof Rack pulled the nutsert through the roof

Hi all,

just curious if anyone else experienced this, and what was done. I had a aluminium ladder (about 6ft) on the roof rack. Weight would be under 20lbs. Was driving down a hill, start slowing down (not hard braking).. and i hear a big bang.. i thought the ladder fell of the roof.. however was still there.. what did happen is the roof rack side rails, at the back have pulled the what look like a certnut through the roof sheet metal.

Have not taken anything apart yet to see exactly what happened, but looks like there is no backing whatsoever behind the sheetmetal where the roof racks are mounted. So if there is weight pushing down on the roof all is well, but when the pressure pulls up, either because your braking, wind resistance etc, then its not designed to well.

These are the factory racks fitted when maunfactured, not a addition after vehicle purchase.

Has this happened to anyone else? Has anyone had a chance to look at the roof without the liner, to see how the racks are mounted? Is mine just an anomoly or are they all just riveted with nutserts to the sheet metal without ant backing.. it seems strange that it would be mounted like this.

now have to work out a way to straighten the "volcano" in the sheet metal where the rivet was pulled out through. i notices on the 3 other mounts at the rear, althought not pulled through completely, it did create a volcanoe from the rivets wnting to pull through.. lucky i dint have anything ~120lbs on the roof.. which is what i think its rated for.
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Old 10-04-2012, 08:22 AM
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Re: Roof Rack pulled the nutsert through the roof

Hi,

I have heard of a few other people experiencing problems with their roof racks, though I don't think with the as little weight as you have described.

I routinely have 100lbs. on mine (a roof-top carrier) on long trips at highway speed and have never had a problem. This has included stopping hard, high wind, etc.

How was the ladder positioned? If it extends far over the front or back, and/oror if your two cross rails are close togetheryou've got yourself a nice big lever. Any force acting on the end of the ladder is going to have an effect much greater than the 20lbs of the mass of the ladder. Could have something to do with it...and, like you say, the forces the roof rack experiences are typically working with gravity, not against it. I believe the owners manual calls for securing the front and rear of loads on the roof that extend past the windshield or hang over the back for just that reason!

Never had a look as to how the main rails are actually fastened to the roof, but based on the weight restrictions we have I never thought it to be too secure.
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Old 10-04-2012, 11:23 AM
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Re: Roof Rack pulled the nutsert through the roof

Ive had a big sofa on mine and it was fine lol!
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Old 10-04-2012, 11:43 AM
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Re: Roof Rack pulled the nutsert through the roof

I recall seeing a thread about a guy that put a surf board on his roof and the "lift" while driving caused the roof bolts to pull through the sheet metal of the roof just as you described.
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Old 10-04-2012, 01:13 PM
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Re: Roof Rack pulled the nutsert through the roof

Quote:
Originally Posted by suzieque View Post
I recall seeing a thread about a guy that put a surf board on his roof and the "lift" while driving caused the roof bolts to pull through the sheet metal of the roof just as you described.
Yes, I forgot about that:

CAUTION!! WK factory Roof Racks
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Old 10-05-2012, 01:51 AM
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Re: Roof Rack pulled the nutsert through the roof

Hi all thanks for the replies.. the ladder was up to about the top of the front window, otherwise could not open the rear door.. having siad that, i am not by any means strong.. and can lift it with one hand without any problems.. its an alumunium ladder.. very light.. I also had in the past heavy items without any issues.. for example a mountain bike, etc.. i actually had the same ladder a number of times in the past without any issue.. so was shocked when this happened this time. i am guessing over time (its only a 2010 model) the sheet metal at the rivets was stretching, without anyone noticing as its hidden by the plastic covers.. until a few days ago, when one decided to give way.
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Old 10-05-2012, 03:59 AM
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Re: Roof Rack pulled the nutsert through the roof

No experience with that specific application but I have delt with nut certs quite a bit. If the hole isn't exact and they aren't installed very carefully they don't work worth a crap. Could be a quality control issue from the factory. I'm not suprised that they do it this way it is cheap and CAN work well if done right. I haven't had the headliner out to see but can you put a bolt, washers and a nut on it? That would be an easy fix and the volcano in your sheet metal will straighten out when you tighten the bolt/nut. Otherwise see if you can finr a nut cert that is larger outside diameter to fit the now stretched out hole. Good luck
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Old 10-16-2012, 04:26 AM
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Re: Roof Rack pulled the nutsert through the roof

Well its getting fixed as we speak, also the place fixing it is making some brackets underneath so this doesnt happen again. I asked him to take pics of what he did just incase anyone is interested.
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