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Roof Rail Bolt Size?


ten25
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I am trying to build and install some custom roof rails to mount solar panels on to.

 

Got the first plug out for the driver side factory mounting location. I had seen an M8-1.25 recommended elsewhere for the regular Transit but seems to big for the Connect, so I tried an M7-1.0 x 40mm and this one fits in the hole, and grabs the edge of the hole, but I can use my finger to tighten it.

 

Due to the length I didn't try to tighten it all the way down but given what I am trying to do (mount solar panels) the grip seems a little suspect and there doesn't appear to be any threading in the hole that the bolt is attaching to (it's just gripping the edges of the hole).

 

Seems like I might need to drill my own holes or maybe I am missing something? 

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On 1/18/2022 at 12:02 PM, ten25 said:

there doesn't appear to be any threading in the hole that the bolt is attaching to

 

There isn't.  It's just a hole.  You will need nuts, washers, lock washers, and probably foam rubber and/or silicone to seal out water.

 

On 1/18/2022 at 12:02 PM, ten25 said:

Seems like I might need to drill my own holes

 

Just use the existing holes under the plastic caps.  

 

On 1/18/2022 at 12:14 PM, ten25 said:

using riv nuts

 

That works just fine.  A lot of installers use rivnuts for roof rails.  You can also open the hole to make it larger, so that you can use a larger rivnut.  That allows you to use a larger bolt, for more strength.  

 

Keep in mind that you are not building your solar panel rack for stationary use.  You have to build it strong enough so that when you are driving, the solar panels and the bracket stay on the van.  Don't be the guy who is driving on the freeway, and the panels fly off.

 

 

I'm 10-8

 

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15 hours ago, Fifty150 said:

 

There isn't.  It's just a hole.  You will need nuts, washers, lock washers, and probably foam rubber and/or silicone to seal out water.

 

 

Just use the existing holes under the plastic caps.  

 

 

That works just fine.  A lot of installers use rivnuts for roof rails.  You can also open the hole to make it larger, so that you can use a larger rivnut.  That allows you to use a larger bolt, for more strength.  

 

Keep in mind that you are not building your solar panel rack for stationary use.  You have to build it strong enough so that when you are driving, the solar panels and the bracket stay on the van.  Don't be the guy who is driving on the freeway, and the panels fly off.

 

 

I'm 10-8

 

Thanks. Going down the freeway and having them fly off is exactly what I am trying to avoid! 
 

The rivnuts that fit without drilling are pretty tiny #8-32. Thinking I will also use VHB tape along the length of the aluminum rail as well, and perform daily checks on it to make sure everything is looking good.

 

 

Edited by ten25
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Looks like I'll be drilling whether I like it or not. Turns out those holes don't even fit the #8-32 (I just thought they would based on the measurements I took before ordering them). At least I can just go ahead and use a bigger riv nut for peace of mind ?

Edited by ten25
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I installed a Weatherguard roof rack and rail system and these were the bolts( just under 5/16) and riv nut type threaded insert that  came for rail instalation.I had to enlarge the roof holes for the insert.I used automotive silicone sealant under the insert flange and a rubber plumbing washer between the flange and bottom of the rail.No leaks  

Thousands of miles in the last 5 yrs with lumber,ladders and a Yakima pod with no issues

20220124_115036.jpg

20220124_115628.jpg

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