Those definitely look like spot welds. Adhesive/sealant was used on the plate to ensure no leakage. Structural adhesive on such a small area wouldn’t be sufficient to sustain design load.
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https://www.bronco6g.com/forum/threads/my-diy-soft-top-roof-rack-build.76663/I do all my own DIY stuff and have made racks for friends rigs. Still playing with some super low profile designs for the Bronco. Any pics of your DIY rack?
Is it possible the area was contaminated by wax, hence the failure?Installed a 175Lb rooftop tent on top of my diy rack.
Bouncing through a hole, popped the plug welded plate off.
Someone had to find the limits
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This might be a good place to start. Also a good way to summon @ZackDanger from the ashes.
https://www.bronco6g.com/forum/threads/roof-rack-100lbs-weight-limit.22665/
I see rust on the underside of the plate at the welds. Was it a part failure/fatigue?Installed a 175Lb rooftop tent on top of my diy rack.
Bouncing through a hole, popped the plug welded plate off.
Someone had to find the limits
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Your rack design is the fundamental problem, very unlikely the vehicle. The lack of rear torsional support placed too much load into the front mounting points.I've got a thread on the rack. Myn was too tall, wasn't sure on height clearance around the soft top at first. Will be going lower for less lever action.
Exactly. Way too much torque on those windshield mounting points. You can't just bolt on things and expect it to support all that weight swaying and bouncing back and forth and expect it to hold. The flaw was in the design of the rack.Your rack design is the fundamental problem, very unlikely the vehicle. The lack of rear torsional support placed too much load into the front mounting points.
There are plenty of Broncos with racks and RTTs that combined weigh way more than the measly dynamic 100 lb load limit I have heard of. These folks wheel hard with no problems.
This is a good possibility. I'll what Ford says, if it is, they'll be taking the other one off too.I see rust on the underside of the plate at the welds. Was it a part failure/fatigue?
Is there a photo of the rack in this thread? I didn't see one.Your rack design is the fundamental problem, very unlikely the vehicle. The lack of rear torsional support placed too much load into the front mounting points.
There are plenty of Broncos with racks and RTTs that combined weigh way more than the measly dynamic 100 lb load limit I have heard of. These folks wheel hard with no problems.
I agree on the problem.Your rack design is the fundamental problem, very unlikely the vehicle. The lack of rear torsional support placed too much load into the front mounting points.
There are plenty of Broncos with racks and RTTs that combined weigh way more than the measly dynamic 100 lb load limit I have heard of. These folks wheel hard with no problems.
I disagree on your view of the problem. No matter how stiff you tried to make it, a single center (and) hitch mount for a roof rack will permit too much torsion of the rack. That leads to the large tension and compression loads at the front corners, of which the tension clearly caused your issue.I agree on the problem.
The height of the racks front blocks were main issue though. Torque is increased further out you are.
Rear of the rack was fine, had turnbuckles installed. No sway/torsion.
Rear is what kept everything sturdy enough to drive home.
I've seen quite a few broncos with rtt as well. Haven't seen any of them wheel their's with the rtt and gear on though.