Reinforce Roof Rack?

chrispitts

Has anyone reinforced the Yakima Roof Rack on a 320S? Perhaps via extending bolts through to the inside? Perhaps adding cross member beams inside?  (The weight limitation appears to be because the rack is only attached to the camper via self-tapping screws that only penetrate one side of the internal aluminum cross-beam. Why not put bolts all the way through? And anchor them to a cross member(s) inside the main unit?) I'm not worried about aesthetics; looking to make the roof rack functional beyond it's 70lb capacity. Thanks for any guidance.

Homebodyatheart

Here’s a few pics of the materials that make up your shell, both inner and outer. The cross pieces are aluminum strips. My vote is to leave everything alone so you don’t mess up your Azdel or framing. 

Homebodyatheart

And here’s your structural beam and framing. You can see where the aluminum cross beams are, 18” apart if I remember correctly. Not my Tab, but probably a 2017-2019 S model. 

Tabaz

I believe the lower attachment point is located under the lower horizontal brace (cannot be seen without removing that brace).  If you remove one of the audio speakers located in the rear cabinet, you'll see a bolt and nut coming in at an angle from the roof.  I'm guessing this is the inside part of the lower bolt holding the Yakima rack to the T@B.  Not sure how the remainder of the rack is secured as it makes its way up the roof.

pthomas745

@chrispitts What year is your trailer?  There are several good threads that discuss the trailer construction and how the roof rack is attached.  (You may have seen these threads, and some of the links are broken).  Here is just one.

https://tab-rv.vanillacommunity.com/discussion/12592/clarification-on-aftermarket-roof-rack-installation

The issue on getting heavier stuff on the rack is the weight and balance of the trailer and sorting out how to keep the tongue weight correct.

ckjs

chrispitts said:

Has anyone reinforced the Yakima Roof Rack on a 320S?…

The sidewalls are a stryfoam and plastic panel sandwich which isn’t designed for much weight, regardless of how things are attached to it. The walls have no hidden “studs”. After upgrading the rack—to-roof mounting, it’s unclear how much additional load it would take before the roof itself or walls start deforming. 

That’s a different kind of excitement than I’m interested in. 

AnOldUR

Not the Yakima rack, but I added a rack to the back of our 2020 320S using the through bolt technique that you described. Ten 3/8-16 bolts that pass through the aluminum cross members. Creeping up on 50K miles on all types of road conditions.

chrispitts

Thanks all. Will be exploring reinforcement options similar to what AnOldUR posted. Replace some of the screws holding the rack today with bolts that go through 3 reinforcement plates on the interior. In addition, securing the outer most of those  plates to the sides of the shelving unit (which then should bring the entire shelving unit and that entire section of roof into play for resistance strength. That's a lot of surface strength as opposed to  currently only a handful of screws into the Azdel)
My 2 bikes combined are less than 60 lbs. So not adding a huge amount of weight. Along with the spare and a couple of ancillary times (collapsed table, outdoor mat, even 2 gallons of fuel) - the total weight is still under 125lbs.
I think the Yakima rack was an 'after-thought' addition to the trailer. So it was mounted 'as best could' to the existing trailer design. Through-bolted on the bottom, but only 'screws into the exterior sheath up the sides and top. Therefore it has the very minimal recommended weight limit of only 70lbs.  (NuCamp doesn't want to change the primary trailer frame construction to accommodate a beefier rack load capacity. (Though I bet it wouldn't be difficult or expensive to do so - and would be a real benefit to future sales to make that rack option more functional)   
I'm confident that with the insights provided by you all here, modifications can be made that don't jeopardize the integrity of the trailer and I'll be able to improve the load capacity/usefulness of the rack. Thanks much.

Marceline

chrispitts said:

Thanks all. Will be exploring reinforcement options similar to what AnOldUR posted. Replace some of the screws holding the rack today with bolts that go through 3 reinforcement plates on the interior. In addition, securing the outer most of those  plates to the sides of the shelving unit (which then should bring the entire shelving unit and that entire section of roof into play for resistance strength. That's a lot of surface strength as opposed to  currently only a handful of screws into the Azdel)
My 2 bikes combined are less than 60 lbs. So not adding a huge amount of weight. Along with the spare and a couple of ancillary times (collapsed table, outdoor mat, even 2 gallons of fuel) - the total weight is still under 125lbs.
I think the Yakima rack was an 'after-thought' addition to the trailer. So it was mounted 'as best could' to the existing trailer design. Through-bolted on the bottom, but only 'screws into the exterior sheath up the sides and top. Therefore it has the very minimal recommended weight limit of only 70lbs.  (NuCamp doesn't want to change the primary trailer frame construction to accommodate a beefier rack load capacity. (Though I bet it wouldn't be difficult or expensive to do so - and would be a real benefit to future sales to make that rack option more functional)   
I'm confident that with the insights provided by you all here, modifications can be made that don't jeopardize the integrity of the trailer and I'll be able to improve the load capacity/usefulness of the rack. Thanks much.

I'm still not convinced its a great idea, but if you decide to go through with it, please be sure that your reinforcement plates don't have any sharp corners.

Tabaz

I have a 2016 Outback with the huge spare tire mounted on the Yakima rack.  I recall only having 25 lbs. of additional weight with the tire in place.  Someone commented that the "flat" weight limit of the Yakima rack can't be used because its mounted on an angle - thus reducing the useful load.

YanniLazarus

I think the biggest issue with the factory installed rack is that it doesn't have a rigid rail following the curve of the roof, which would spread weight load more evenly over the aluminum cross members than the flexible rail currently used.  Admittedly, I haven't heavily loaded my rack, but I favor the rigid rail approach. 3 years use now. 

RCB

The loads imposed on the roof racks shown in the pics all are ultimately transmitted to the side walls of the trailer. I have some pics of the aluminum framing but cannot tell how they are fastened, but I suspect they are screw fastened at the aluminum tube at the top of the wall. For that reason I would prefer to extend the roof rack to the top of the side walls so the loads are imposed on the wall and not to any part of the roof.

I would remove the vinyl trim and install at the location for the rack a length 8-10” of aluminum angle say 2 1/2 x 2 1/2 x 1/4. This piece can be slightly curved by a fabricator to match the top curve of the wall. Make a plywood template. The angle can be screwed to the top and side of the alum wall piece. Cut the vinyl moulding and reinstall to allow for the size the roof rack hardware mounting bracket. Fasten the roof rack bracket to the aluminum angle. Be sure to use a suitable caulking at all fastening locations.

Now, I have not done this, but I would not retrofit a roof rack to the roof of my 400 such that loads are imposed onto the trailer roof. I recognize that there are certainly some field issues with this idea, but perhaps this is food for further thought.

AnOldUR

YanniLazarus said:

… 3 years use now.

I believe we did our roof rack mods about the same time. I admired your approach of connecting to three of the roof rails, Glad to hear it’s proven to have worked well. Mine only uses two of the frames cross members, but has also held up. If I get motivated, I have plans to remove the rectangular steel tubing and replace it with longer solid aluminum bars to spread the load out closer to the side walls. Also, I was getting water in the steel tubing and saw signs of rust. Probably not a necessary change, but a good winter project.

YanniLazarus

Thanks for the kind words,  anoldur. Us older T@Bers do seem to thrive on a winter project or two.

MPuyot

I'm new and bought a 2021 TAB320.  I would like to find a way to carry an outdoor rug on the roof rack, so I dont have to bring such a dusty item in the trailer with towing.  Has anyone done a carrier for such a task?  I am thinking I could bring the two Yakima crossbars closer together and mount a large diameter plastic tube (say 8" diameter by the width of the roof) using some kind of U-clamp.  I think it will work but curios if anyone has done something like this?

Sharon_is_SAM

I think you can also mount a hose carrier under the rear bumper.  Just roll up the rug.

Yoshi_TAB

Hi,

 Another option is to buy a car/truck cargo box if your tow vehicle has side rails.  We use it to keep our rug, side tent and chairs.  It comes in handy if it rains and everything is wet when it’s time to leave.

MPuyot

excellent points.  Also, I just checked Amazon for "RV rugs" and found there are lots of "plastic straw" rugs that fold up nicely and go into a convenient carry bag.   That seems like the easiest path so think I will go that way.  Thanks for the inputs.  https://www.amazon.com/GENIMO-Outdoor-Waterproof-Foldable-Reversible/dp/B0CLLG44SN/ref=sr_1_1?crid=Q1SR05QPIP08&dib=eyJ2IjoiMSJ9.wixgX1fLU-zyNOMG-ZXYv_4SMy-BgsXITtLntwaKCrXe5-C4TfiyDdeLC3xujzFJLpRNGb1bGsZi1yuyV44U84j3bMXJMKsMm2LjMMRIxwmZZaML7oztUCZc4SjlXZQbvhVtG5CYeIk1Zkp9n0bRdi19Q21PahkX_MEuCRSS52r74vSbGKulgpV1FjN55YHLicbmnHPrQR127U0NdJsshg53AjQ3jIc9riuYUi99mI-SqqD_yQQi8TykkGJvobRc-6BSTlAoqazRx_RK_Ht5DBVxKirISWoOlpdnob7AJzw.jglHk9OU55a7xk6XjAgpbIB0MCcJaxEh8VWRPOc_wgE&dib_tag=se&keywords=GENIMO%2B6%27%2Bx%2B9%27%2BOutdoor%2BRug%2BWaterproof%2Bfor%2BPatio%2BDecor%2C%2BFoldable%2BReversible%2BPlastic%2BStraw%2BArea%2BRugs%2BMat%2Bfor%2BCamper%2C%2BOutside%2BCarpet%2Bfor%2BRv%2C%2BDeck%2C%2BPorch%2C%2BPicnic%2C%2BBeach%2C%2BBalcony%2C%2BBlue%2B%26%2BGrey&qid=1727315741&sprefix=genimo%2B6%27%2Bx%2B9%27%2Boutdoor%2Brug%2Bwaterproof%2Bfor%2Bpatio%2Bdecor%2C%2Bfoldable%2Breversible%2Bplastic%2Bstraw%2Barea%2Brugs%2Bmat%2Bfor%2Bcamper%2C%2Boutside%2Bcarpet%2Bfor%2Brv%2C%2Bdeck%2C%2Bporch%2C%2Bpicnic%2C%2Bbeach%2C%2Bbalcony%2C%2Bblue%2B%26%2Bgrey%2Caps%2C226&sr=8-1&th=1