How To Repair A Thule Box Car Top Carrier
- Tape The Damage Together From The Front Side. Use masking tape to hold the cracks together. Do not try and apply the...
- Remove Any Dirt, Grease, or Paint From The Back Side. Remove any dirt, grease, or paint from the back side. You need to...
- Apply The Resin Directly From The Applicator Bottle.. Apply the resin directly from the...
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.
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?
How do you repair a broken box?
Our box repair methods have come a long way over the past decade or so. Initially (in the late 1990s) we would apply ABS "patches" - cut pieces of ABS plastic attached by ABS cement - to the hole or cracked section of the box. This would be a pretty good solution, but ran the risk of coming apart after a couple of years.
How to fix cracks in a box?
Is the repaired box pretty?
Can a Thule box be repaired?
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.
How do you fix a Thule box lock?
1:042:46How to remove and replace a Thule roof box lock - roofracks.co.ukYouTubeStart of suggested clipEnd of suggested clipBox either turn the key slightly clockwise or anti-clockwise towards the marked unlocked. PositionMoreBox either turn the key slightly clockwise or anti-clockwise towards the marked unlocked. Position this should be approximately 45 degrees from the normal locked.
How do you fix a car roof box?
0:283:01How to fit a luggage box - YouTubeYouTubeStart of suggested clipEnd of suggested clipMake sure the fixations clamp the roof ranks very tightly to prevent any movement whatsoever. YouMoreMake sure the fixations clamp the roof ranks very tightly to prevent any movement whatsoever. You may now attach the two restraining straps always use them to secure the load while driving.
Can you repair a cracked roof box?
Fix the roof box into a position where gravity will pull epoxy into the crack. Then work the epoxy into the crack with a mixing stick or a small brush, or inject the epoxy using a syringe. Use a fine blade or stick to push the epoxy as far into the crack as possible.
Can you replace Thule locks?
You will get 2 locking keys and 1 master key with your Thule product. If you don't have the master key, you can order a new one from Thule retailers or directly from Thule.
How do you open Thule cargo without key?
Remove the plastic lock cap and expose the metal key hole and lock barrel. Position the drill bit into the dead-center of the metal barrel. Carefully bore out the lock cylinder. Take great care to go in straight and not drill the plastic edges of the cargo box.
How do Thule cargo boxes attached?
0:103:10How to Install a THULE Cargo Box - YouTubeYouTubeStart of suggested clipEnd of suggested clipThese feet and hooks on the bottom are what grab onto the crossbar. And as you can see they canMoreThese feet and hooks on the bottom are what grab onto the crossbar. And as you can see they can slide up and down to accommodate the spacing of the crossbar.
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.
How much weight can a Thule cargo box hold?
WarrantyVolume18 cu ftHeight off crossbar16.1 inLoad capacity165 lbMounting systemPowerClickWeight47 lb17 more rows
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 are Thule boxes made of?
Made of high-quality ABS material, these cargo boxes are built to protect your gear and last.
How do you paint Thule boxes?
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.
Can you replace the lock on a roof box?
The first step will be to unlock your current lock, (if you are replacing a lock for a roof box, you need to position the key diagonally between the locked and unlocked position). Take out your key and insert the Master Key. Now you are able to slide out the old lock and insert the replacement.
How do you remove a Thule lock cylinder without the key?
0:511:24How to remove Thule lock cores without a control key - YouTubeYouTubeStart of suggested clipEnd of suggested clipThat down and just push on the backside of that locking core and they'll start to push out. Then allMoreThat down and just push on the backside of that locking core and they'll start to push out. Then all you have to do is grab the core and the key kind of wiggle it. It. Will pop right. Out.
How do you remove a Thule lock plug?
Expert Reply: There is a small gap between the plastic cap and the outer edge of the lock core hole that is just large enough to allow you to insert a small, flat tool such as a flat head screw driver. Once you have the tool inserted, you will pry upward forcing the cap out.
Where do I find my Thule key code?
The Thule Key Code can be found on the head of your original key or on the face of the lock. The Code will begin with the letter N followed by 3 digits eg: N001. This number must be provided to enable us to cut your key.
Small Crack in Thule Top Box Fix? | Expedition Portal
Sorry to say, but that crack is probably evidence of a much larger fracture. To do it right you will most likely have to disassemble the thing, grind and re-glass the fracture from inside and outside, as well as reinforce the joint further to avoid the same failure later on.
Best repair of a crack in black rooftop cargo boxes a la Thule/Yakima ...
Get a flat piece (thin) of similar material. Rough it up on the inside with some 40 grit. And rough up the patch. Clean it with acetone, quick wipe only as it might melt the plastic a bit.
How to repair crack in roof box - Teton Gravity Research
The old Thule roof box is showing it's age. When I take it off in a few weeks, I already have to fix the front hinge, which basically rotted off at one point. But, yesterday I leaned on it the wrong way, and a small, three inch crack appeared at the stress point where it attaches to the rack in the rear. Not too bad right now, but, what can I do to seal and re enforce this crack so that it ...
How To Repair A Damaged Thule Box - YouTube
This Video Demonstrates how to repair a damaged Thule Car Top Carrier Using an Easy ABS Repair Kit https://easyabsrepair.com/
How To Repair A Cracked Thule Roof Box - Top Roof Top Companies!
Easiest Method to Get Your Roof Repaired or Replaced After Being Damaged by a Storm or Hail – How To Repair A Cracked Thule Roof Box. Roof Replacement and Hail Damage
How to fix cracks in a box?
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. Depending on the cement you get, the stuff may set up quite fast. Be sure to have the fiberglass patches cut and ready to go in advance.
Is the repaired box pretty?
The repaired box. It's not pretty but it was free, which is right up our alley .
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.
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.
How many cracks in a box?
Most damaged boxes will have one or two cracks (ranging from a couple of centimeters to a couple of feet) or even a hole or two. And not every box that has been damaged is even repairable. Some holes or cracks are simply much too large to be repaired at all, and some injuries occur in "sensitive" areas to the box, meaning the structural integrity of the box has been compromised. If this is the case, we will tell you so, and your only recourse will be to purchase a new box.
Is a cargo box as good as new?
In the end, the box does not look as good as new, but it works. While a repair such as this is not inexpensive ($150 and up), it is certainly cheaper than a new $700 box. So if you have a cargo box that is injured, come see us and we will see if we can help you.
Can a cargo box survive an underground?
While it takes quite a collision to completely shatter a cargo box (unless it is very cold out), it is rare that a box will survive an underground with nothing more than a few red or yellow scratch marks.
Can a broken piece fit a hole?
In a best case scenario, the broken piece is not lost and is able to fit its hole (like a puzzle piece). However, most of the time the piece goes missing, and I have to cut a piece of ABS plastic off of an old box to fit the hole:
How to fix cracks in a box?
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. Depending on the cement you get, the stuff may set up quite fast. Be sure to have the fiberglass patches cut and ready to go in advance.
Is the repaired box pretty?
The repaired box. It's not pretty but it was free, which is right up our alley .