Repair a Thule Rooftop Carrier
- Products
- Repair the Damage. If you are starting with a hole, start by adhering some strong, thick plastic over it using epoxy. ...
- Fill in the Gaps. It still looked pretty rough and uneven, in spite of careful sanding down. ...
- Spraypaint. ...
- Recap. ...
Full Answer
How to repair a Thule roof carrier?
Repair a Thule Rooftop Carrier 1 Products 2 Repair the Damage. If you are starting with a hole, start by adhering some strong, thick plastic over it using epoxy. ... 3 Fill in the Gaps. It still looked pretty rough and uneven, in spite of careful sanding down. ... 4 Spraypaint. ... 5 Recap. ...
What happened to our Thule rooftop box?
A few months before we left, when we were still deciding what system to use to carry our camping gear, we found a discarded Thule rooftop box laying on the side of the road. There were big cracks on both sides but otherwise it was in decent shape. The box was locked when we found it so we paid $5 to get new keys made at a locksmith.
How do you fix a crack in a fiberglass box?
We lightly sanded down the area of the crack extending 6"-8" all around. We applied a layer of ABS cement to the surface of the box, laid down a layer of fiberglass, and brushed more cement on until it was saturated. We repeated with a second layer using a slightly larger fiberglass patch.
Is this an acceptable finish for a Thule?
Nevertheless it was an acceptable finish. My new improved Thule had gone from a giant hole to a sleekly repaired and functional rooftop carrier. Did you make this project?
Can you fix a cracked Thule box?
0:483:55How To Repair A Damaged Thule Box - YouTubeYouTubeStart of suggested clipEnd of suggested clipThe area one quarter inch on each side of the crack should be cleaned down to the raw. Plastic.MoreThe area one quarter inch on each side of the crack should be cleaned down to the raw. Plastic. Apply the resin directly from the bottle. There is no mixing or adding of catalysts or hardeners.
How do you fix a broken roof box?
Below is the suggested approach.Step 1: sand the area. Working on the inside of the box, start by sanding the area around the break. ... Step 2: clean the area. ... Step 3: flame-treat the plastic. ... Step 4: warm everything up. ... Step 5: mix your epoxy. ... Step 6: Apply the epoxy. ... Step 7: add extra strength.
What are Thule boxes made of?
From the Manufacturer The Thule 614 Pulse L Roof Box offers consumers the additional space they need at an affordable value. The roof box has a 14 cubic foot interior capacity, and is constructed of rugged ABS plastic.
Are Thule roof boxes waterproof?
Description. The cargo bags & boxes are weather resistant. Exposure to dirt, dust, and light precipitation for a short time should not affect the contents inside the carrier. The hard shell carriers, or boxes, are the most water resistant but are not waterproof.
Can ABS plastic be repaired?
0:064:47How to repair and reinforce large ABS plastic items using ABS slurry.YouTubeStart of suggested clipEnd of suggested clipIn this video I'll show you how I used an ABS plastic slurry to repair and reinforce a large itemMoreIn this video I'll show you how I used an ABS plastic slurry to repair and reinforce a large item made out of ABS plastic. Which in this case is roof of our rooftop tent.
What plastic are roof boxes made from?
ABS plasticUnless stated, all the boxes we sell are made from various types of UV-protected ABS plastic, and they are fully recyclable.
How do you pronounce Thule?
Though it isn't spelled phonetically in English, “Thule” isn't difficult to pronounce. The correct way to say it is “too-lee,” Rack Outfitters reports.
How much weight can a Thule cargo box hold?
WarrantyVolume18 cu ftHeight off crossbar16.1 inLoad capacity165 lbMounting systemPowerClickWeight47 lb17 more rows
Where are Thule roof boxes made?
Thule is a Swedish company. But while some products are indeed made in Europe, 75% of the Thule products sold in North America are actually made the USA. Thule has factories in Seymour, CT and Chicago, IL. As an added bonus, Thule recently installed a 318-kilowatt solar array on the roof of its CT facility.
How fast can you drive with a Thule roof box?
186 mphIt's integrated onto a removable roof panel and is certified for speeds up to an incredible 186 mph. Even if you don't have a supercar in your garage, Thule's roof boxes have always been industry leaders with regard to aero efficiency and low noise levels, but the company's newest innovation goes a step further.
Are rooftop boxes worth it?
Improved Weight Distribution. When compared with a rear-mounted cargo box a rooftop cargo box offers much better weight distribution. The load is spread across the car rather than adding extra weight at the back of the vehicle.
Do roof racks affect gas mileage?
When just the roof rack was added, the car's mileage dropped by almost 11 percent, or 5 mpg. But with the rack and rooftop carrier installed, the overall drop was 19 percent, a loss of 9 mpg. As we found when we tested roof- and hitch-mounted bike racks, the SUV's mileage, on the other hand, showed less of a drop.
How do you paint a cargo box?
0:0311:10How to Paint a Roof Cargo Box | CRV Van Life - YouTubeYouTubeStart of suggested clipEnd of suggested clipAnd yeah so first off the main thing you just need to prep. And clean the surface super well andMoreAnd yeah so first off the main thing you just need to prep. And clean the surface super well and then you can paint.
How do you clean a roof box?
Simply take the following steps:Using soapy warm water, clean the surface of your roof box then leave it to dry for a minimum of 12 hours. ... Using a cloth or brush, apply a generous amount of Polytrol to the surface. ... Wipe any excess away using a lint-free cloth.Leave it to dry.
Can Thule bike racks be repaired?
We offer many spare parts for our products. For warranty cases, please turn to your dealer to repair your Thule product. For out of warranty repairs our dealers can provide you with spare parts as well.
Tape The Damage Together From The Front Side
Use masking tape to hold the cracks together. Do not try and apply the resin between the cracks as this will distort the box. Taping the damage together as tightly as possible will keep the shape while you begin the repair from the back side.
Remove Any Dirt, Grease, or Paint From The Back Side
Remove any dirt, grease, or paint from the back side. You need to get down to the raw plastic. The resin will melt into the plastic and bond the new ABS in the resin to the box. The resin cures in about 24 hours to a hard finish the same as the original plastic.
Apply The Resin Directly From The Applicator Bottle
Apply the resin directly from the applicator bottle. There is nothing to mix or add. The resin will flow out and smooth as it cures. The resin is about the same constancy as thick yogurt and will stay where you put it. You can apply it upside down or on vertical surfaces and it will stay in place.
Continue The Repair From The Front Side
Remove the tape from the front side. I use a Dremel Tool to groove into the cracks. You can also use a knife or file to make the groove. Groove out 50% to 75% into the plastic.
Fill The Groove From The Front
Fill the groove with resin from the front side. You want to fill the groove completely, do not over fill as you will sand the repair. You can add more resin if needed after the first application is cured. Apply the resin directly from the applicator bottle. There is nothing to mix or add. Let the resin cure for about 24 hours.
Sand The Repair Smooth
Sand the repair flat an smooth with the surrounding plastic. Do not use any two part bondo type fillers to even out the repair. This material will not stay bonded to the plastic and will crack and flake off. Use the same resin as a filler it will weld in place and never come out.
Finish The Repair, Final Sand, And Paint
The repaired area will sand and accept pain the same as the original surface because it is the resin is the same ABS plastic. Trying to repair plastic with any epoxy type product will not sand smooth because the Epoxy is so much harder than the plastic.
If you have cracks in your Thule or Yakima rooftop cargo carrier, then a roll of Gorilla Waterproof Patch and Seal Tape might give your carrier an extended life of keeping your gear dry
A couple of years ago I bought a rooftop cargo carrier (Thule Sonic XXL roof box) from a seller on Craigslist. The individual had never used the carrier as it was dropped at some point before it made it to the top of his vehicle. The force of the drop cracked the back portion of the lid.
Updates on Fix with Gorilla Waterproof Path and Seal Tape
It has been around seven months since my initial repair of my cracked cargo box. I have had the cargo carrier on top of my vehicle so the repair has seen snow, rain, sun and strong winds. I can report that there has been no water leaks or peeling of the tap from the cargo box. It all looks great.
Step 2: Repair the Damage
If you are starting with a hole, start by adhering some strong, thick plastic over it using epoxy.
Step 3: Fill in the Gaps
It still looked pretty rough and uneven, in spite of careful sanding down. That is when I turned to my next product: the Flex Seal. I taped off the area and tried to fill the low spots with several layers of spraying. I laid it on really thick and spread it while it was still wet with a putty knife.
Step 4: Spraypaint
I removed the taped off area from the previous step and then retaped leaving an extra 3-4 mm gap so that my final finish would totally overlay the Flex Seal. I then sprayed over the whole area again using Tremclad rust paint. The paint is supposed to match the colour of the cap, but I found it to be quite a bit lighter than the look of the cap.
Step 5: Recap
My new improved Thule had gone from a giant hole to a sleekly repaired and functional rooftop carrier.
