Quote:
Originally Posted by jmcelroy
Mine have been working fine. I use the cross bars for a top box, bike racks, and a Yakima basket and swap out regularly.
Could be a difference in carriage bolts. Sounds like you have something perfectly flush the with cross bar that that is not sitting flat due the the square boss protruding. If I had that problem I'd look at fixing it like this:
1) Use different carriage bolts that have a shallower square section. This might be a PITA. I don't know what standards exist for them (I'm an engine builder, not a chassis guy . . . this is the only time I've really used carriage bolts in an automotive application)
2) Knock the corners off the carriage bolts a bit on the bench grinder. Not all of it, just the part that protrudes.
3) Use a washer with an I.D. large enough to fit over the square section so the square boss no longer sits proud of the cross bar
4) Grind/drill a relief in whatever you're mounting so the square protrusion doesn't not prevent it sitting flat on the bar
Jason
p.s. - I realized the thread spec I originally wrote was wrong and corrected a few days ago. TBH, the thread form doesn't matter, just the diameter. (SAE, Metric, USS, Whitworth, Acme, etc . . . it doesn't matter)
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Thanks for the suggestions! Carriage bolts would've been perfect, but it was easier to run back to HomeDepot and get 2 new regular bolts. Kind of a pain to get a socket underneath it, but just a little jiggling and it worked.
I agree about the dimensions of the carriage bolts. It was a pain enough to find the ones that I did. I might try a trip to Lowes or Ace to see if they have other ones that might work better. But, for a future project. These are already on there and no need to re-do them.
Love all of the insight and experience from this forum!