If you’ve got a cracked roof box, you don’t always have to toss it out. You can save some serious cash by repairing it yourself, but knowing how to approach the job makes all the difference. A busted roof box could lead to leaks, reduced security, or even harm your car’s roof if it’s not fixed right.
Common Causes of Damage
Knowing what led to the damage in the first place can save you from future trouble. Roof boxes often suffer from cracks, dents, or busted latches due to:
- Overloading the box beyond its weight limit.
- Exposure to extreme weather conditions.
- Mishandling when mounting or dismounting it from the car.
Water leaking into the roof box is a red flag for cracks, and you might notice your items are wet after a rainstorm. Keep an eye out for any cracks, especially around the edges.
Inspecting the Damage
Before grabbing any tools, the first step is to do a thorough check. You gotta look for cracks, dents, or broken latches. Even minor cracks can become a big problem on the road, especially if water gets in. To find the cracks, simply run your fingers along the box or use a light to find the weaker spots. Always look around the latches and hinges too—they’re usually the first to break.
Materials You Need for Repair
You don’t need to go overboard with tools. Simple stuff like:
- Epoxy resin or plastic adhesive (for cracks).
- Fiberglass patch kits (if the crack is big).
- Sandpaper (to smooth down rough edges).
- Spray paint (to make it look fresh after the fix).
Most of these materials are easy to get from hardware stores. Fiberglass patch kits are your go-to for larger cracks because they offer more durability than standard adhesives. A government advisory on safe roof box repairs suggests that when choosing adhesives, opt for epoxy resins known for bonding plastic tightly. Look at verified brands for this kind of job.
Repairing Small Cracks
For smaller cracks, epoxy resin is your best friend. It seals up tight and stays waterproof.
- Start by cleaning the cracked area with a damp cloth and let it dry completely.
- Use sandpaper to smooth down the edges of the crack.
- Apply the epoxy resin according to the product’s instructions.
- Let it cure for a few hours before testing it by lightly pressing around the fixed area.
For plastic roof boxes, epoxy is a solid choice as it offers strong adhesion, creating a lasting seal. Most minor repairs can be handled with epoxy and sanding, and it’s essential to test the box afterward.
Patching Large Cracks
Larger cracks call for more serious work. A fiberglass patch kit is highly recommended for bigger issues because it reinforces the box and stops cracks from spreading.
- After sanding the damaged area, cut the fiberglass patch to cover the crack with extra room.
- Apply the resin, lay down the patch, and smooth it out with a putty knife.
- Let it dry, then sand down the area until it’s even with the surface of the box.
Fiberglass patches hold up better than plastic adhesives for larger cracks. Be sure to paint over the repaired area after the fix so that it blends well with the rest of the roof box.
Fixing Damaged Latches and Hinges
Sometimes it’s not just cracks that you’ll deal with—latches or hinges can also break. Broken latches are more than just an annoyance; they’re a security issue. Replacement latches are widely available, and installing them is pretty straightforward.
- Remove the damaged latch using a screwdriver.
- Install the new latch by following the manufacturer’s instructions.
- Always test the new latch a few times to ensure it’s secured properly.
For hinges, you might need to replace the entire hinge or just tighten some screws. Always check your roof box’s specifications for compatible hardware.
Fix It, Don’t Replace It
A damaged roof box doesn’t mean it’s time to buy a new one. With a few simple materials and the right steps, you can repair most cracks or broken latches. Always remember to regularly inspect your roof box after each trip, especially if you’re dealing with heavy loads.
