Roof Rack Keeps Failing

[Bill T]

Looking for advice on what my next step shout be. My RCI roof rack keeps bending on the side where my awning is mounted.. The first time it bent, RCI required I purchase a replacement rail for $40 because I did not have the freedom panel rail mounted.

My tent and awning are nothing out of the ordinary weight wise. Maybe 250 combined.

Now it has bent again, and I don’t know if I should stick with the rack and find a way to fix it again, or scrap it and find a stronger brand. It always seems to fail while on a trip requiring in field fixes to get home.

ideas or suggestions anyone?

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[604Bronco]

Did @RCI Offroad say that you need to install another part in order for it to support the awning weight? Seems strange it would fail twice, unless some additional part wasn’t installed.

 

[RallyGorgo]

May need to step up to a better/stronger rack, TrailRax perhaps.

 

[Brian_B]

I don't know anything about the RCI rack in particular, but this is pretty prominently placed on their web site for the rack. Dunno if it would make a difference or not, but sounds like you just got too much lateral load for a long piece of railing there.

I don't see "Filler plates" as an acessory for that rack, or "Freedom Panel" - just the "extrusion stiffener", which may do what you want, I don't know

https://rcimetalworks.com/product/roof-rack-extrusion-stiffener/

I'd say it's worth another call into them, see what they recommend first, before you just potentially throw the baby out with the bath water.

 

[AK SNO RIDER]

 

[Bill T]

Did @RCI Offroad say that you need to install another part in order for it to support the awning weight? Seems strange it would fail twice, unless some additional part wasn’t installed.

Yes, so first fail was on me, but after installing freedom panel access rail, another failure occurred.

 

[RC Bronco]

Yes, so first fail was on me, but after installing freedom panel access rail, another failure occurred.

Please share pictures of the first failure and the second failure

 

[Bill T]

I don't know anything about the RCI rack in particular, but this is pretty prominently placed on their web site for the rack. Dunno if it would make a difference or not, but sounds like you just got too much lateral load for a long piece of railing there.

I don't see "Filler plates" as an acessory for that rack, or "Freedom Panel" - just the "extrusion stiffener", which may do what you want, I don't know

https://rcimetalworks.com/product/roof-rack-extrusion-stiffener/

I'd say it's worth another call into them, see what they recommend first, before you just potentially throw the baby out with the bath water.

Thank you for responding. Good advice, and I will call them to see what they stay, but this recent fails is AFTER having the filler panels installed. If they offer a NEW solution, that would be promising, but my concern is they offer a replacement rail with filler, this will become Charlie Brown trying to kick the football Lucy is holding for him.

 

[broadicustomworks]

You will probably end up with one of two options, if I were a betting man:
1. Buy a heavier duty rack system altogether.
2. DIY your own solution to reinforce the side rails. Meaning something like 2x2 angle (aluminum would be lighter but more $$, would not rust) with holes drilled to match holes in their rails, longer bolts to go through the stiffener. Gussets to the crossbars may work but the 2x2 is the simplest and easiest way, most bang-for-the-buck.
just guessing.
Some pics would help us to help you with some remedy.

 

[AK SNO RIDER]

You still haven't given us any detail to go off of. How heavy is your awning and how is it attached to your rack? Is it bolted right to the side rail or is it attached to the actual crossbars like it should be? How many mounting points are you using. Just 2, or 3-4?

There's a big difference between a 74lb bush company awning incorrectly mounted to the side rails and a 35lb FSR awning that's been properly mounted.

 

[Hemisfear]

This is not the first time I have heard of this style of roof rack breaking...

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