Roof Box

How To Repair A Cracked Roof Box? Ultimate Guide In 2023

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Roof boxes are an absolute game-changer for those looking to transport extra gear on their vehicle. So one question pops up, How To Repair A Cracked Roof Box if it got damaged?

In this article, we will dive deep into the causes of roof box cracks, the different types of cracks, and how to diagnose them. We will also explore the feasibility of fixing a roof box and the various options available for repairs.

In short, Fixing a roof box is possible with 5 easy steps we will be showcasing in our article, moreover, we recommend trying to prevent the roof box from cracking in the first place for more info scroll down.

What Cause A Roof Box To Crack?

Roof boxes are a fantastic way to add extra storage space to your vehicle, but they’re no stranger to damages and cracks.

Heavy loads are one of the most common culprits of roof box cracks. Overloading the box beyond its weight capacity or unevenly distributing weight can wreak havoc on the box.

Weather elements like intense sunlight, rain, snow, and hail can also cause the box to expand and contract, leading to cracks.

Also, let’s not forget about accidents. Even minor collisions or low-hanging branches can cause significant damage to the box.

But perhaps one of the most frustrating causes of roof box cracks is material defects. Poor quality materials or manufacturing defects can result in cracks, even with normal use.

What Are The Types Of Roof Box Cracks?

Hairline cracks are the first type of crack and are small and usually found on the surface of the box. These cracks can be caused by various factors, including exposure to sunlight or cold temperatures. Thankfully, hairline cracks are easily fixable by applying sealant.

Minor cracks are the second type and are more substantial than hairline cracks, potentially impacting the structural integrity of the box. Minor cracks can occur due to overloading the box or exposure to extreme weather conditions. Repairing minor cracks involves more work but can be done by applying sealant and sanding down the surface.

The third and most severe type of crack is a major crack. These cracks are severe and can lead to unsafe driving conditions, often caused by accidents or material defects. Attempting to fix major cracks is not recommended, and it may be best to replace the entire unit.

How to Diagnose Roof Box Cracks?

Maintaining the safety of your vehicle is crucial, and diagnosing any cracks in your roof box is a key part of that. Luckily, there are several ways to do this, including visual inspection, tactile inspection, and water testing.

Visual inspection is the most obvious way to diagnose any cracks in your roof box. Simply look for any visible cracks or signs of damage on the surface of the box. Check for any changes in texture or discoloration that may have occurred due to harsh weather conditions.

A tactile inspection involves running your hands over the surface of the roof box to feel for any irregularities or bumps. Pay attention to any spots that feel softer or more pliable than the rest of the surface, as these could indicate a larger problem.

Water testing involves filling the roof box with water and observing whether any leaks occur. If there are leaks, there may be a crack or other damage that needs to be addressed. Check the interior of the box for any signs of water damage, such as mold or mildew.

Can You Fix A Cracked Roof Box?

If the crack is minor, then you can go on and certainly start fixing a roof box on your own. All you need to do is clean the area around the crack, apply a sealant, and sand it down once it’s dry more information on that later on. But what about more severe cracks?

Well, in case of severe damage or cracks in critical areas of the box, it may be time to replace the entire unit. Trying to fix significant damage on your own can further compromise the integrity of the roof box and lead to unsafe driving conditions. Safety should always be a top priority, nonetheless, we recommend contacting the manufacturer or any professional repair shop.

How To Fix A Cracked Roof Cargo Box?

Whether you’ve found a minor or major crack in your roof cargo box, there are some options for how to repair a cracked roof box that can suit your needs.

A minor crack can be a great opportunity for a DIY roof box fix, which can save you money and be done on your own schedule.

Steps to fixing a roof box:

  1. Sand the surface around the crack and clean it thoroughly.
  2. Apply fiberglass tape over the crack.
  3. Mix the epoxy resin according to the instructions and apply it over the tape.
  4. Smooth it out and let it dry completely.
  5. Paint it to match the rest of the roof box

Here is a video on how to repair a cracked Thule roof box

Alternatively, if the crack in your roof cargo box is major, professional repair may be necessary. This type of repair can be expensive but ensures the repair is done safely and correctly.

Depending on the severity of the damage and the availability of repair services, the timeframe for professional repair may vary.

Contacting the manufacturer or specialized repair service can be a good starting point to have your roof cargo box professionally repaired. The box may need to be removed from your vehicle and repaired in a controlled environment.

If you are wondering how a professional roof box repair might look like on a major crack check out the next video

How To Prevent A Roof Box From Cracking?

Regular Inspection

Proper maintenance of your roof cargo box is essential for its longevity and your safety. You need to regularly inspect your roof cargo box before and after each use, as well as at least once a month if it’s stored outside.

Inspect the box for any cracks, scratches, or signs of wear and tear, and address any issues immediately would prevent any cracks from getting larger, hence getting harder to repair.

Proper Storage And Loading

When not in use, ensure that you store the box in a dry, covered area. Don’t store it in direct sunlight or extreme temperatures, which can cause damage to the box material.

Proper loading is also vital to prevent stress and damage to the box and your vehicle, as well as a safety hazard on the road. Follow the manufacturer’s guidelines for weight and loading capacity and distribute the load evenly across the box.

Avoidance of Harsh Weather

harsh weather conditions can cause damage to your roof cargo box. Avoid driving in extreme weather conditions like high winds, heavy rain, or snowstorms.

If you must drive in such conditions, ensure that the box is securely fastened and that the load is appropriately secured and distributed.

Conclusion: How To Fix A Cracked Roof Box?

Your roof cargo box is an essential accessory for outdoor enthusiasts, but maintaining it is critical to its longevity and safety. Weather elements, heavy loads, accidents, and material defects can cause roof box cracks. Minor cracks can be repaired with a DIY approach, such as applying adhesive and pressure, while major cracks require professional repair.

In conclusion, fixing a cracked roof box is possible, but the severity of the crack will determine the repair level required. By following proper maintenance and care practices, you can prevent cracks from forming and ensure your roof cargo box lasts for years. Taking care of your roof cargo box is essential to ensure safe and enjoyable outdoor adventures.

With that being said, we hope you found our answer to the question How To Repair A Cracked Roof Box? valuable and pleasant, and if so, please assist us by sharing it, since sharing drives us to create more relevant content.

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