Thread: Roof Load

as I understand it the official weight limit for the disco on the roof is 75kg, I know expedition vehicles in the uk can and do carry up to double that without problems but you might have issues with insurance, or just being classed as an unroad worthy vehicle if you go over the official limit, also I would imagine the handling gets interesting with 100 plus kilos on the roof!

The legal limit is 50KG for a Disco 1. Just do a google search on it and you will find that answer. THis is the legal roof weight limit, and you have to take the roof rack weights out of that too! However we all know they will take much more than that but if you had an acciddent you could be in trouble with the law and insurance companies.

I have a Front Runner roof rack, EziAwn RTT and a Hanibal type swingout awning on my DI which up until recently I thought was okay and within limits.
Today I took the car to my workshop complaining of a sound coming from the top of the windshield just above the front pillars. It appears that over time my roof has parted company with the car at these two main points.
I was shocked to say the least since the only thing keeping the roof on at the front of the car was the glass!
Now the roof lining, windshield etc has to come out for major rebuilding and welding. I discussed the possibility of strengthening the joints with the workshop manager but apart from welding brackets inside the roof to the top of the B pillars we don't know what else to do.
I'm going to have to rethink my camping strategy now with a lighter load!

What do you estimate the weight that you have had up there. Any chance of some pics of the damage?

I have had a stack of weight up there for a long time on some very bad roads. So far, so good.

I have three 10" wide feet on each side of an alloy rack. Oz Tent, spare wheel, space case full of stuff, awning, tube full of tent poles and a bit of camping gear. I think there would be almost 100kg there.

The worst part is the handling, you notice the difference straight away when it is loaded. I bought 30mm wheel spacers and it improved it a lot. Yes, I know they are not legal but I think it makes the car safer. I spoke to guys that have had them for years on D1's and Defenders with no issues.

My two bob's worth is... don't put fuel or water up there. I got sill tanks and a water bladder to keep the CoG low. Get an alloy rack, otherwise half your weight is in the rack. Take it off when you don't need it.

Here's the crack...it's the same on both sides of the car and in the same position at the top of the windshield pillar.
Weight wise, I have a Front runner aluminium rack which weighs about 40kg. Ezi-Awn roof tent that weighs around 50kg and a swing out awning that weighs around 10kg.
The surrounding area has a fair amount of surface rust but the cracks are through good quality steel.

A negative point about the roof rack is that it has rather narrow supports...I'm thinking of making them wider to distribute the weight in the rain gutter....possibly even bridging them all together with a 6 foot long piece of aluminium rod.

Thoughts on this idea?

Jesus streaky that aint pretty. As for your question on longer mounts for the rack, my old RR classic had an ARB steel roof rack which had a full length rail that sat in the gutter. At the time this was ARB's selling pitch, spread the load across the whole roof. It does make good sense to me.

What, may I ask, is it going to set you back to have that fixed

Ozzie $ is around $550 since the roof liner has to come out, windshield removed and replaced with new seals. Both sides needs welding, painting etc.
I also asked if they can strengthen this segment of the roofs structure but don't yet know if they can do this to any substantial degree.

My Ezi-Awn roof tent has always been towards the front of the car which can't help matters. However, I've just placed an order for a lighter full length tent which in theory will distribute the load along the entire length of the roof.
I'm going to ask my work shop to widen the gutter mounts too.