Prinsu Rack, Cross Bar Bolts Rusting, One Bolt Sheared Off

[Farzad_K]

Hello.

To my dismay I have found out that most of the cross bar bolts are rusting. One bolt sheared off as I was trying to make adjustment to the bar's position and I have no idea how to get that bolt extracted without taking it into a machine shop.

I have written to Prinsu about it and am hoping to hear from them soon. I wonder if others may have experienced rusting and how you dealt with it, and if you have suggestions on how to get the sheared bolt extracted.

Thanks a lot.

Farzad

 

[je32188]

There's probably an easier way without buying extra shite, but my first thought is a screw extractor set. Something like: IRWIN Screw Extractor for Spiral Screws, 5-Piece (53535) - Hand Tool Sets - Amazon.com

 

[crawlingjunk]

Screw extractor. And then use anti seize on the bolts Dis similar metals corrode way easier. Being steel and aluminum


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[TK-422]

Not that it helps you for the sheared bolt but when I installed mine 6 years ago I used stainless steel TORX security bolts instead of what was supplied. The same goes for the roof mounted bolts.

I did it for security as well as rust prevention.

I use stainless steel wherever I can to prevent this from happening.

 

[Farzad_K]

Not that it helps you for the sheared bolt but when I installed mine 6 years ago I used stainless steel TORX security bolts instead of what was supplied. The same goes for the roof mounted bolts.

I did it for security as well as rust prevention.

I use stainless steel wherever I can to prevent this from happening.

You did the smart thing; I trusted the popular manufacturer for having taken corrosion into account. I think I need to replace all the remaining screws with SS, but I also want to hear back from Prinsu.

Thanks

 

[Farzad_K]

There's probably an easier way without buying extra shite, but my first thought is a screw extractor set. Something like: IRWIN Screw Extractor for Spiral Screws, 5-Piece (53535) - Hand Tool Sets - Amazon.com

Thanks

 

[Farzad_K]

Thanks

 

[lewdog998]

That is one of the reasons I don't like that design. All off the weight is put on the shear strength on the bolt...so if much of you weight umis on one crossbar, it could be overloaded. That's the main reason I like the front runner....the crossbars ride on the inside of the channel of the two main rails...like you would design a roof. Its not relying on two bolts to hold all the weight.

Good luck removing it. Might be less headache to just replace the one bar.

 

[Andrea]

This is the problem with dissimilar metals especially aluminum and stainless steel. The aluminum most likely expanded due to corrosion and is gonna be a SOB to get out. If it was me I would undo all the screws I could. Spread the sides of the Prinsu rack out and remove the cross bar. Heat and beat with a hammer to loosen bolts and hopefully there is enough room to get vise grips on the broken off heads threads.

Then put Cadium Plated Hardware back in. This page has expired

 

[Farzad_K]

This is the problem with dissimilar metals especially aluminum and stainless steel. The aluminum most likely expanded due to corrosion and is gonna be a SOB to get out. If it was me I would undo all the screws I could. Spread the sides of the Prinsu rack out and remove the cross bar. Heat and beat with a hammer to loosen bolts and hopefully there is enough room to get vise grips on the broken off heads threads.

Then put Cadium Plated Hardware back in. This page has expired

I am going on a trip, and when I come back I intend to remove all the cross bars and toss the bolts and get new ones. I need to figure out what to do with the residual corrosion inside the holes. I want to clean them up. Prinsu is not getting a good review from me with this design. It is strange that I am the only user of this rack that has reported the problem.

I might live with the one bar having one screw at one end and not load that bar. But if I have to wrestle to get the sheared bolt out I might just buy a replacement bar.

Why cadmium?

 

[Farzad_K]

That is one of the reasons I don't like that design. All off the weight is put on the shear strength on the bolt...so if much of you weight umis on one crossbar, it could be overloaded. That's the main reason I like the front runner....the crossbars ride on the inside of the channel of the two main rails...like you would design a roof. Its not relying on two bolts to hold all the weight.

Good luck removing it. Might be less headache to just replace the one bar.

Yeah, and I am hoping Prinsu will replace that bar for me and tell me what to do to save the rack.

 

[T4R_Canuck]

Hello.

To my dismay I have found out that most of the cross bar bolts are rusting. One bolt sheared off as I was trying to make adjustment to the bar's position and I have no idea how to get that bolt extracted without taking it into a machine shop.

I have written to Prinsu about it and am hoping to hear from them soon. I wonder if others may have experienced rusting and how you dealt with it, and if you have suggestions on how to get the sheared bolt extracted.

Thanks a lot.

Farzad

Should be an easy enough job to extract that broken bolt with a few applications of some penetrating fluid and a screw extractor set, which can be found at at local hardware store. If that fails, just find a drill bit slightly smaller than the bolt size and drill the broken bolt out.

I live in the great white north and have the same rack. I actually just relocated some bars today so I had a good look at my hardware and after 2 Canadian winters all hardware is looking good. I personally use blue loctite on every bolt because i'm really concerned about things loosening over time, but I would suggest putting some sort of grease on your hardware at minimum. I noticed my baja rack fuel holder came with a packet of grease that they suggest using on their hardware.

It would appear by your pictures that your hardware was installed dry, which led to moisture getting in and causing your rust issue.

Best of luck!

 

[iamatt]

Heat. Aluminum expands crazy some heat should separate the metal and rusty threads. Might have enough exposed to tack a bolt on there, giving you a place to turn and heat at the same time.

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[akhero]

Quality control?

 

[TK-422]

The original Prinsu designer sold out his designs to another company soon after I bought my rack. I was one of his last customers. I will say he was very on top of the quality. I have no say on how it is since.

The all aluminum design was made to save weight but is also pretty strong. There are between 8 and 11 crossbars depending on your setup and with 4 bolts for every one it spreads out the load pretty evenly.

I have thrown up a lot of weight on mine over the years and it has never let me down. This is the only picture I could come up with which isn't much but it has held much more.

 

[jbtvt]

Sherpa uses stainless hardware that come in black oxide finish and their prices are good. You could buy replacements from them if it's the same size. I've never had luck heating bolts stuck in aluminum, it's too effective a heat sink in my experience, but would also recommend a screw extractor and lots of liquid wrench over several days. If you have a welder you could also weld a nut onto the stud (after soaking stud in penetrant), but if you snap that the remaining piece will be tempered and even more difficult to drill out

 

[Farzad_K]

Thanks everyone.

Prinsu sent a replacement part almost immediately. They acknowledged the issue and stated that some customers replace the stock bolts with stainless steel bolts as some of you have also suggested.

I am looking to get these bolts as replacement. They are 1/4" shorter than stock bolts and that only affects the amount of torque you can put on the hole threads since they are weaker than the stainless steel. However, I intend to test one of them at 30 ft-pound which is the tightness specified for the original assembly. I also intend to use anti seize during installation.

Farzad

 

[jbtvt]

Anti seize affects the torque reading and will make it more likely to strip, and is unnecessary if using stainless. I used blue loctite

 

[Farzad_K]

Anti seize affects the torque reading and will make it more likely to strip, and is unnecessary if using stainless. I used blue loctite

What about the residual rust in the holes? Would that not interfere with the locktite?

 

[jbtvt]

Doubt to where you'd notice but you could blow them out with compressed air or brake cleaner if you're worried. The surface insensitive Loctite is better for some contaminated surfaces