Advisory: Baja Racks

[1engineer]

I have the flat utility rack on my '12, and it's doing the same thing, although not as severe as OP. My typical load is either a canoe or a skybox, nothing out of the ordinary. To me it's clearly a design flaw that needs to be addressed by BR.

These were installed in good faith, assuming the design was tested and the potential load placed in the proper spots. Obviously putting any of that load outside the channels is a bad idea, as it turns out.

I sent everything over to Baja to see how they want to address this, so we'll see. Dents and dings happen, but as mentioned, eventually this will crack through the paint and be a much larger issue.

Guys, I don't follow every thread or know everything about every product out there. Now, looking at this picture, I'm surprised that every single one of these racks that has had any load or have been grabbed from the sides to hoist something up or even using ratchet straps on the sides have not dented the top.

Personally if I ordered one of these and saw how they mounted, I would send them back. Just my opinion.

 

[jimster716]

I emailed them yesterday morning just to inquire about lead times for a rack and to install in their parking lot (which I read is common). Haven't heard a peep, they're either busy or based on your experience, they aren't very responsive. Maybe I'll just bite the bullet on a Gobi.

Well since they still haven't responded to me and this issue appearing on several vehicles, I decided to pay a little more and bit the bullet on a Gobi Stealth rack. If this could happen on the Gobi is unknown, what is known is that Baja customer service appears to leave a bit to be desired.

 

[Snooperstyle]

Wow, I need to go check mine. I have had some heavy stuff up there before. And I've also done some other (not necessarily smart) things that could put a lot of pressure on one of the feet...for example, I tied one end of a hammock to the rack and the other to a tree...or when you are stuck in the mud, then standing on the sliders while rocking the vehicle with your hands on the rack...

I wonder if Baja racks had an inconsistent run of some racks where those round steel spacers were slightly off??? I wonder how they ensure quality control? People who can confirm denting should post a purchase and shipped date.

 

[bboy626]

I'm thinking the integrity of the roof frame underneath the painted surface is good. Unless the surface where the roof rack foot mounts to/touches, are made from some strong steel and not aluminum, the foot should be redesigned to not touch any part of the painted surfaces. Wonder if other manufacturer foot designs also touches the painted surfaces and if they have similar issue.

 

[Keith_PDX]

Mine came directly from Baja through Metal Tech on May 10, 2015.

 

[1engineer]

Could someone post pics from a bit further away on how these racks are mounted?

 

[coversion]

Could someone post pics from a bit further away on how these racks are mounted?

 

[1engineer]

...

Thanks.

 

[K9trainer]

Are the feet (mount point) welded to the rack?
If not- take the feet and bolt them to the roof, toque them down, see if there putting pressure on the sheet metal. If they do it not the rack / weight causing the damage, it the poor design of the mounting brackets.

 

[Simpleman74]

Are the feet (mount point) welded to the rack?

picture above they clearly are not.... just a shotty design

 

[1engineer]

Are the feet (mount point) welded to the rack?
If not- take the feet and bolt them to the roof, toque them down, see if there putting pressure on the sheet metal. If they do it not the rack / weight causing the damage, it the poor design of the mounting brackets.

Judging by the pics posted above, what's causing the dents is a combination of lateral and compressive forces being applied from loading. For example, using the rack as a handhold to get up there in addition to the rack being heavily loaded. Just my opinion.

 

[coversion]

Judging by the pics posted above, what's causing the dents is a combination of lateral and compressive forces being applied from loading. For example, using the rack as a handhold to get up there in addition to the rack being heavily loaded. Just my opinion.

If the damage is done so to speak, I don't have a huge issue with it. However, if this is the beginning of what will end up looking like OP's (or worse), then it has to go.

Possible solution could be to add a washer to each bolt under the feet to lift the "wings" of the feet off the roof and only on the channels, but then all of that force is moved to the area under the washers and not across the entire foot. It also seems that trimming the feet to fit the channel would weaken it vertically, given the design.

1e, what are your thoughts? Anticipate it worsening? Worst is done? Any ideas/solutions in front of us to prevent further damage short of taking it off?

 

[wild_turkey]

If the damage is done so to speak, I don't have a huge issue with it. However, if this is the beginning of what will end up looking like OP's (or worse), then it has to go.

Possible solution could be to add a washer to each bolt under the feet to lift the "wings" of the feet off the roof and only on the channels, but then all of that force is moved to the area under the washers and not across the entire foot. It also seems that trimming the feet to fit the channel would weaken it vertically, given the design.

1e, what are your thoughts? Anticipate it worsening? Worst is done? Any ideas/solutions in front of us to prevent further damage short of taking it off?

That's a good idea. I remember I asked [MENTION=117648]Jabberjaw[/MENTION] about the install before I installed mine and he mentioned being careful about over-torqueing the bolts and potential for dents. A light bulb should have gone off that adding a load would cause a similar effect.

I can see the beginnings of some dents in a couple of places. I have stood on the rack a couple of times (200 lbs) and I imagine they will only get worse with the additional weight of my RTT and wife.

Seems like Bajarack could offer a simple solution by shipping out some aluminum shim plates with pre-drilled holes to fit over the plastic tubes such that the metal tubes on the mounting feet would interface the plate and distribute the majority of the load across the plate rather than the roof areas that are getting dented.

Unfortunately, this does not help the OP who already has significant denting. I feel for you man. I will probably be in a similar spot if I can't get this fixed before our camping trip next weekend.

Sub'd and I will try to contact Bajarack as well.

 

[1engineer]

If the damage is done so to speak, I don't have a huge issue with it. However, if this is the beginning of what will end up looking like OP's (or worse), then it has to go.

Possible solution could be to add a washer to each bolt under the feet to lift the "wings" of the feet off the roof and only on the channels, but then all of that force is moved to the area under the washers and not across the entire foot. It also seems that trimming the feet to fit the channel would weaken it vertically, given the design.

1e, what are your thoughts? Anticipate it worsening? Worst is done? Any ideas/solutions in front of us to prevent further damage short of taking it off?

Personally I would use it for a roof top carrier mount and a cooler mount but I wouldn't use it to swing myself up and dance around on it. How do the other racks mount?

Let's be honest - most people don't use them very much (if at all) and bought it for the looks and the dream of maybe one day getting off the couch and out into the woods. This forum proves that.

I think adding a washer under the spacer would help take the pressure off the sheet metal but then you will lose the lateral stability that the foot in contact with the body gives you.

I would think that if you continue to load it heavy and mount awnings and RTT's or use it for a hand hold that the bending will continue. I don't think just putting a static load on it (pure compression) would cause the damage you guys are seeing. I do think uneven loading (again, grabbing it on one side to pull yourself up or using it as a ladder stand) could be problematic if the weight was large enough. Just my opinion. I think this manufacturer makes a quality product and I know a lot of people are happy with it but, as with any product from any manufacturer including Toyota, damage can occur in certain situations. I agree with the OP as this should not be a "bash" thread but an awareness thread.

I think ANY rack out there, including OEM, will cause damage to the vehicle if you aren't careful. Nothing is indestructible. Just my .02.

 

[96r50]

I don't see why they have to make the feet that big. The rack should only make contact with the truck in the drip channel not the sheet metal of the roof. While the substructure of the pillars and roof are designed to hold up to some serious force (rollovers etc) the only place to tap directly into that structure is in the drip channel itself. Having large rectangular feet that cover the roof and outer roof rail sheet metal is a recipe for damage (as noted in this thread unfortunately). I'm really quite surprised they would design the feet like that.

Hopefully they'll come up with an amenable solution for those with damage and redesign the feet from here on out.

 

[Keith_PDX]

Seems like Bajarack could offer a simple solution by shipping out some aluminum shim plates with pre-drilled holes to fit over the plastic tubes such that the metal tubes on the mounting feet would interface the plate and distribute the majority of the load across the plate rather than the roof areas that are getting dented.

This is exactly what I did, seen in the first photos. The rack now sits a good 1/8" off of the sheet metal in all areas. I used a thicker adhesive weather stripping foam to fill the air gap.

Sergio from BajaRack contacted via Expeditionportal. I will be in discussions with him. I will let you all know how it goes.

http://www.expeditionportal.com/for...ic-Advisory-Baja-Racks-5th-generation-4Runner

 

[Keith_PDX]

Here is what the feet look like now with the aluminum spacer in place. I've always ran a piece of 3M clear bra. I added thicker/denser foam to take up the gap.

I spoke with Sergio on the phone and they have designed new feet and will have them in production next week. They will remain in the channel and not touch any painted metal. I got the impression they will be wider (front to rear of vehicle). Stay tuned.....

 

[1engineer]

Good stuff. Glad they are working with you.

 

[Swede71]

that is good to hear, will they be shipping them to all of us that have their current racks? To replace the existing ones.

 

[Swede71]

I spoke with the guys at The Gear Shop in Calgary today, and they have not had any customers complain about this as of yet. So that is good to hear then.