Let me fill in your logic, engineering and mathematical gaps and help your "thinking" process. I will let [MENTION=66316]1engineer[/MENTION] explain the difference between static and dynamic weight ratings to you if self initiated Google or the free clues below don't fill that gap for you first. From Baja's website "Load Capacity: Dynamic (while driving) 300Lb (136 kg); Static 600Lb (272 kg)". Load capacities of the rack do not include the 80lbs of the rack itself. Although I have tried several times to occupy the tent while I drive (free hint on the word "dynamic"), I have not been able to succeed. Thus the dynamic state of the setup is approximately 160lbs at best with the bedding and whatnot inside the closed tent. When were parked and occupying the tent (free hint on the word "static") the load on the rack is at most 460lbs with people and personal affects.
The factory rack rating has nothing to do with the rating of the roof, which no one publicly knows that I have been able to find.
Specifications can be found here: Baja Rack: racks_list_inside
I had the exact same thing happen about 7 months ago. The vehicle was about 1 month old at the time so I wasn't real happy about it. I contacted Baja rack at the time and they were as helpful as they could be. Not too much they can do as the damage has already been done. They sent me out new mounting hardware but I ended up just keeping the old mounts up there. I had a paintless dent repair guy look at it and he said "why bother", so I said screw it and don't worry about it anymore. Now I will throw any thing up there, heaviest load so far was an entire elk. If you have a baby elephant you can put it in my rack, whats it going to do, dent my roof? This was a result of the mounting brackets being out of spec. When I first mounted them the plate that the rack sits on was not parallel to the ground, as you tighten the rack to the mounts it caused the little wing portion of the mounts to dig into the roof. While they might be hard to get a hold of at times Baja Rack seems to have good customer service. They actually called me at home last Friday thinking I was the OP of this thread trying to solve this issue (my name is Keith also). I am pretty easy going when it comes to my vehicles but I can see where some people might come unglued over this issue.
New Brackets.....
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is that BAJAs design or something you created?New Brackets.....
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So I talked to someone from Baja today at the Overland Expo (I believe it was Sergio).
He stated that if you want replacement feet, send them an email with your address and they will start shipping them in about 2 weeks.
He said the issue was caused by wear in the tooling, meaning earlier ones shouldn't have an issue, but they will replace them for anyone who wants.
He seemed pretty upset that this issue happened, and is doing what he can to the rectify issue.