Defender Roof Rack Issues & Tuff Coating Q's

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94 TLC

94 TLC

Joined
Oct 25, 2008
Threads
22
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163
Location
Phoenix
Hi All!

My girlfriend and I are avid day trippers in the greater Phoenix area. Although, two weekends ago, we ventured 7hrs up to Moab, UT for a long weekend. That was a blast! A random pic attached.

I have a Defender a roof rack that I really like because it doesnt cover the sun roof. I purchased it at 4wheel parts in Mesa, AZ about a year ago. Unfortunately the drill-into-the-roof rubber/nut roof mounts failed miserably and now I am stuck with a dozed drill holes in my roof. I want to remount the rack and wonder how other mounted their Defender Roof Rack. Has anyone else had this problem? Recomendations?

Also, I am very interested in putting a tuff bedliner like coating on the side panels of my rig. I know there is a few good posts on how to do this on IH8MUD but I can find them. Help?

We're looking forward to our next trip up to the Flagstaff area. Until then, happy wheelin'

Thanks!

Charlie
Failed Roof Mount #1.webp
Failed Roof Mount #3.webp
DSCN1675.webp
 
Sweet Ride!

As far as your roof rack goes it can be fixed. You need to find an industrial fastener company and get some nut rivets from them in a size that will fill the holes you have.

Next look at how your racks weight is supported and make sure you have some type of flexibility. Your rack stayed solid as the roof flexed pulling them out. This is why gutter mounts work best for racks and RTT applications.

JM2C
 
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Fill the holes with your method of choice. FastSteel, JBWeld, WaterWeld, etc.

Bed line the roof with your product of choice (Duplicolor, LineX, etc).

Get gutter mounts for your roof rack.


The way that rack was mounted was good for about 100 lbs. (That 100 lbs isn't including the weight of the rack. So if that rack weights 40 lbs, you got about 60 lbs carrying weight.)
 
Now that you explain that, it make perfect sense. I used it for a trip to New Mexico and by the time I got back, the thing was rattling like mad. Thanks for the info! Appreciated.
 
94 TLC said:
Now that you explain that, it make perfect sense. I used it for a trip to New Mexico and by the time I got back, the thing was rattling like mad. Thanks for the info! Appreciated.
Click to expand...

The OEM rack spreads out the weight a lot better than that setup, it also weighs a fraction (it's mostly plastic). So with 100 capacity, you can carry a decent amount of stuff in it, I've loaded it up multiple times with decent amount of weight, probably never pushed the 100 lb limit. The OEM rack actually isn't a bad setup for light stuff, though I almost never use it. I took it off the :princess: rig, might put it back on after I take care of the slight rust/wear around the nutserts.

That rack is designed for gutter mounts, I don't think it'll work well any other way.
 
To reiterate, the way that rack was mounted was horrible! Using rubber wellnuts to hold it on, was a terrible idea. Heck with a large flat item stored up there, it could catch the wind and pull the rack right up off of the roof, not to mention that with the feet just setting out there in the open, unsupported area of the roof, the carrying capability is definitely lacking. Oh yeah, hinges are meant to move, and I don't think you want the rack moving once you get it mounted, hinges probably helped contributing to the rattle as well.

No other way then to pony up and fill the holes and paint or bedliner over them, then properly support the rack with some gutter mounted cross bars.

Did you install the rack, or did someone do that for you? I won't give you too much flack if it was you, but if it was a "professional", you ought to roast 'em!
 
If you want to continue using the rack you have, but want to mount to the rain gutters, order some crossbars and gutter mounts from Groucho on this board at TallowPot Products--Custom Sheet Metal, CNC Machining and Design Work. Bolt your rack to the crossbars (because your rack is too narrow to use without them). For a little added insurance, check out the "Triple Dog" supports on our website (click the link in my sig line).
 
Did you install the rack, or did someone do that for you? I won't give you too much flack if it was you, but if it was a "professional", you ought to roast 'em![/QUOTE]


I had just got my rig and installed the rack myself per the instructions of the manufacturer and the dealer that I bought the unit from. They first sold me the gutter mounts but when I wnet to install it, the rack wasnt even wide enough to reach the rain gutters so I had to go back to the retailer with my problem and they sold me a "slick" method of mounting the rack. I never even loaded the rack heavily with anything before it started failing. Lesson learned on my part. In hind sight it seems so obvious that was a porr installation method. What the heck do they sell those mounts for, I wonder....
 
IMHO, those types of mounts only work well in an application where you can drill all the way through the roof and put a backing plate on the inside. Of course, many people don't want to go that "extreme" to install a roof rack. In fact, I don't recommend using rivnuts for any roof rack mounting points for exactly the reasons you've, unfortunately, discovered.

FYI, the correct width for an 80 series is 48" or wider, to be able to use the gutter mounts. You could always sell (return?) your existing rack and get a wider one......
 
I like the size of my rack because it fits behind the sunroof - leaving an unobstructed sun roof opening. I'd like to keep the rack as low profile as possible too. (keeping it as tight/close to the roof top as possible) Any recomendations? I wonder how far off the roof the TallowPot modifications would be.
DSCN1367.webp
Roof Rack.webp
 
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Here's a rack we built for a '97....it is a platform rack (we also offer basket racks), but the same idea: https://forum.ih8mud.com/ca-socal-80s/403472-diamondrax-roof-rack.html?highlight=diamondrax. It stops shy of the sunroof opening.....

With the Tallow Pot clamps (we sell the identical ones), the clamp itselft adjusts from about 5.25" to just under 6" from where it attaches to the rain gutter to where it attaches to the rack or crossbars. So, add the crossbars on top of that and then your rack's height and you'll have an idea of how tall, overall, you'd be.
 
That's a nice looking platform rack. So.... If I were to need say a 48"W x 60"L x 4"H rack w/ a mesh floor, front fairing, and 4 light mount tabs in front and 2 light mount tabs in the rear, where would I go to see what that looks like? How would I find a price for something like that?....
 
Could this be modified to include a wire mesh (or equal) floor, and 6 light mounting tabs? I've been waiting to install my lights until I had the rack situation resolved. It get daaaark out on the trails under an Arizona sky. My brights definitely do not cut it.
 
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