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johnnyd



Member Since: 13 Apr 2013
Location: Chippenham
Posts: 1006

United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
Thule box on frontrunner roof rack
Hi All

Has anyone put a Thule luggage box on a front runner roof rack, i.e. are the slats in the roof rack a suitable size for the clamps to clamp around securely?

JD 2008 TDCi 2.4 XS CSW
Post #558052 22nd Aug 2016 4:35pm
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Jimb1978



Member Since: 05 Sep 2012
Location: Huddersfield
Posts: 804

England 2002 Defender 110 Td5 Black LE Java Black
I don't know for definite as I haven't got a Thule box or a front runner rack. However, I do have a Hannibal rack and fit a roof box on there for camping trips. The only difference I can see is the slats run left to right on the front runner rather than front to back on the Hannibal. They look a similar width of around 100mm, so I would think the clamps supplied would not reach.

Also, most roof boxes are designed to slot over roof bars to reduce wind noise, and therefore will not sit flat on an expedition rack.

To solve this I made some oak bars which bolted to the rack with home made u bolts. I couldn't source online any square shaped u bolts the right size. I then recessed the brackets that came with the roof box into the oak. (Not the best description and I haven't got any pictures of this.)

The main difficulty was left to right positioning of the box due to my rack slats running front to rear. This might not be an issue with the front runner.

Hope this helps, and if I can take a picture tomorrow I will post it up 2002 110 td5
Post #558127 22nd Aug 2016 9:05pm
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Jimb1978



Member Since: 05 Sep 2012
Location: Huddersfield
Posts: 804

England 2002 Defender 110 Td5 Black LE Java Black
It also whistled unbearably at first. Trapping a foam camping mat between the rack and the box solved that issue 2002 110 td5
Post #558129 22nd Aug 2016 9:08pm
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Caterham



Member Since: 06 Nov 2008
Location: Birmingham
Posts: 6260

England 2011 Defender 110 Puma 2.4 XS CSW Stornoway Grey
could you not simply ditch the U bolts / brackets and using 2 nuts / 2 washers / 2 bolts in each of the 4 fixing locations simply bolt the roof box to the roof rack slats. the slats will accept a certain size bolt so just go with that size. granted it wont be easy lining the nuts / bolt up but I'm sure it can't be too difficult?

good luck.
Post #558308 23rd Aug 2016 1:54pm
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Jimb1978



Member Since: 05 Sep 2012
Location: Huddersfield
Posts: 804

England 2002 Defender 110 Td5 Black LE Java Black
That could work but you would only be able to get one fixing in each of the four locations due to the clamps pointing front to back on the roof box and still have to fill the gaps with a 50mm thick spacer. However, a penny washer to spread the load could replace the need for two bolts. 2002 110 td5
Post #558315 23rd Aug 2016 2:31pm
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johnnyd



Member Since: 13 Apr 2013
Location: Chippenham
Posts: 1006

United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
Now I'm looking at one of these 3 wolf box holdall type things, any comments?
http://www.4x4overlander.com/product/hanni...uble-copy/

JD 2008 TDCi 2.4 XS CSW
Post #558333 23rd Aug 2016 4:01pm
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Jimb1978



Member Since: 05 Sep 2012
Location: Huddersfield
Posts: 804

England 2002 Defender 110 Td5 Black LE Java Black
Yep, use those too. They are very difficult to load unless you can stand on your wing tops and bonnet if you load at the front or a drop down tailgate if you load at the back.

If you can access them they are brilliant though. Transfer to your tent and job done 2002 110 td5
Post #558345 23rd Aug 2016 4:54pm
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johnnyd



Member Since: 13 Apr 2013
Location: Chippenham
Posts: 1006

United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
Hmmm those boxes are too small, struggling here, what do people here use for storage on a roof rack, just normal holiday stuff, thats easy to secure ?

JD 2008 TDCi 2.4 XS CSW
Post #559327 27th Aug 2016 2:09pm
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Organic



Member Since: 05 Oct 2015
Location: Shropshire
Posts: 21

United Kingdom 2012 Defender 90 Puma 2.2 SW Orkney Grey
Hello,

I've attached a Thule to our Flatdog roof rack using S.S. M8 bolts, the adaptor kit and 4x 25mm thick wooden blocks.The bolts are secured to the rack with nylock nuts and suitable washers.

The box is offset to accommodate our Oztent RV4 and accessories bag.


Click image to enlarge


Last edited by Organic on 28th Aug 2016 7:41am. Edited 1 time in total
Post #559383 27th Aug 2016 7:41pm
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DOOFER



Member Since: 07 Oct 2012
Location: Suffolk
Posts: 412

i've got a full length front runner rack on my 90 with an ARB roof tent and three wolf boxes up front. one each for me, wife and daughter in an xl front runner bag. rule is, if you can't get it in your box, you can't take it.

we also have two more wolf boxes in the back of the 90, one for cooking and crockery and one for food.

this set up works perfectly for us and encourages us from bringing too much crap. DON'T PANIC
Post #559390 27th Aug 2016 8:03pm
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johnnyd



Member Since: 13 Apr 2013
Location: Chippenham
Posts: 1006

United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
Hi Organic, which adaptor kit did you use, there seem to be many, also is it easy to get any pics of the arrangement you made for the rack? Looks cool on top Very Happy

JD 2008 TDCi 2.4 XS CSW
Post #559430 28th Aug 2016 6:19am
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bpman



Member Since: 21 May 2008
Location: Oslo
Posts: 8069

2008 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black
I'd say organic has the right idea, maybe pop down to b&q and buy a couple of lengths of steel or aluminium, put the under the rack and bolt thru from the roof box mountings ... Simple
Post #559436 28th Aug 2016 6:46am
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Organic



Member Since: 05 Oct 2015
Location: Shropshire
Posts: 21

United Kingdom 2012 Defender 90 Puma 2.2 SW Orkney Grey
johnnyd wrote:
Hi Organic, which adaptor kit did you use, there seem to be many, also is it easy to get any pics of the arrangement you made for the rack? Looks cool on top Very Happy

JD


Hi Johnny,

My box is the Touring 200. Halford ordered the two adaptor kits in for me to compare that fitted. The only difference I could see was the U-bolt length and you're not going to be using them anyway! My main concern was obviously ensuring a rack slat was within the slot range of the box. The slots are quite long so had no problems. My receipt says I purchased the T-track Adaptor 697003.

I measured the distance between the box slots then secured the M8 bolts with a washer and nylock nut. I worked out the bolts needed to be 80mm long. I'll see if I can grab a photo later.

There is a gap between the rack slots and the actual bottom of the box which you'll need to pack. I looked at using rubber but it would have been way too expensive so I cut, drilled and painted wooden blocks.

Sorry, no pictures of assembly. I hope the above helps.

Paul.
Post #559442 28th Aug 2016 7:24am
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Organic



Member Since: 05 Oct 2015
Location: Shropshire
Posts: 21

United Kingdom 2012 Defender 90 Puma 2.2 SW Orkney Grey
I'm sure the frontrunner and flatdog racks are very similar. Here's an image showing my rack slats.


Click image to enlarge
Post #559459 28th Aug 2016 8:09am
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johnnyd



Member Since: 13 Apr 2013
Location: Chippenham
Posts: 1006

United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
If anyone has any spare time, a diagram of what might be required would be fantastic, I will only have about 4 days to make this work before the trip to Scotland, At the moment I don't have the Thule box, I don't have the roof rack, I don't even have the Defender LoL as its with Zagato being treated, so it's all guesswork for me ATM.

JD 2008 TDCi 2.4 XS CSW
Post #559536 28th Aug 2016 3:09pm
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