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Thread: D4 roof rail fixing ripped off internal mounting

  1. 4th August 2021, 03:24 PM #1
    David Hannett
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    D4 roof rail fixing ripped off internal mounting

    Hi brains trust - looking for advice please for a temporary and/or permanent repair for D4 roof rails where an internal fixing has ripped out of the sheet metal that it was bonded/welded to (see photos) assume cause was thousands of km of corrugated road where threaded part has loosened sufficiently to create enough movement to rip it from the sheet metal (carrying approx 70kg on the roof) there is zero spare thread to permit insertion of a plate - any/all advise much appreciated thanks

    15A58371-8B90-4FCD-B12B-77FB478F45C9.jpeg1C978A23-9419-4AD3-8840-1B3FEA66A714.jpeg2D3684D4-8B07-4B4E-8F38-860A6C18CCD5.jpeg
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  2. 4th August 2021, 04:15 PM #2
    Trevor Cock
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    Not sure if a rivnut (nutsert) would work or be suitable in this situation, a bit hard to tell from the photos.
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  3. 4th August 2021, 04:26 PM #3
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    DieselLSE
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    David, can you advise what sort of rack system you had and how the load was positioned?
    As for the repair, I can only suggest consulting a few panel beaters for advice.
    Please keep us posted.
    2013 D4 expedition equipped
    1966 Army workshop trailer
    (previously SII 2.25 swb, SIII 2.25 swb & lwb, P38 Vogue, 1993 LSE 3.9V8 then HS2.8)
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  4. 4th August 2021, 04:36 PM #4
    Aussie Jeepster
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    I'd be looking at a rivnut/nutsert as well.
    2012 L320 Range Rover Sport Fuji White
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  5. 4th August 2021, 05:05 PM #5
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    Quote Originally Posted by Aussie Jeepster View Post
    I'd be looking at a rivnut/nutsert as well.
    Can't see that being strong enough as parts of the panel have been ripped out.
    2013 D4 expedition equipped
    1966 Army workshop trailer
    (previously SII 2.25 swb, SIII 2.25 swb & lwb, P38 Vogue, 1993 LSE 3.9V8 then HS2.8)
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  6. 4th August 2021, 05:19 PM #6
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    scarry
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    If you are going to continue using a rack,getting it fixed by a good panel shop is the only way.
    Rivnut or nutsert will never be a successful repair,it will come loose in no time,and it needs to be waterproof.
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  7. 4th August 2021, 05:21 PM #7
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    Tombie
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    Panel shop job. No short cuts there.
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  8. 4th August 2021, 05:23 PM #8
    David Hannett
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    Quote Originally Posted by DieselLSE View Post
    David, can you advise what sort of rack system you had and how the load was positioned?
    As for the repair, I can only suggest consulting a few panel beaters for advice.
    Please keep us posted.
    D4 is MY11and rack has been installed from near new so getting on for 10 years old - rhino cross bars with wheel platform and spare wheel/tyre on off-side and half width steel wire basket with 4 x maxtrax on side that has failed - persistent squeak/rattle prompted us to remove headliner to find the failure cheers
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  9. 4th August 2021, 05:54 PM #9
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    DieselLSE
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    Quote Originally Posted by David Hannett View Post
    D4 is MY11and rack has been installed from near new so getting on for 10 years old - rhino cross bars with wheel platform and spare wheel/tyre on off-side and half width steel wire basket with 4 x maxtrax on side that has failed - persistent squeak/rattle prompted us to remove headliner to find the failure cheers
    Thanks for that. Is the roof platform mounted to just four of the six available captive nuts? If so, that may explain the failure. The roof dynamic load is 95Kg and that assumes all six mounting points are used to spread the load. Your load of 70Kg (wheel alone is close to 60Kg I think) would only have been distributed across four mounts I suspect.
    2013 D4 expedition equipped
    1966 Army workshop trailer
    (previously SII 2.25 swb, SIII 2.25 swb & lwb, P38 Vogue, 1993 LSE 3.9V8 then HS2.8)
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  10. 4th August 2021, 06:02 PM #10
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    Quote Originally Posted by DieselLSE View Post
    Thanks for that. Is the roof platform mounted to just four of the six available captive nuts? If so, that may explain the failure. The roof dynamic load is 95Kg and that assumes all six mounting points are used to spread the load. Your load of 70Kg (wheel alone is close to 60Kg I think) would only have been distributed across four mounts I suspect.
    75kg I think you’ll find D4 roof rail fixing ripped off internal mounting
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