How do I fix this?!

[T-Bagg]

Jumped the truck...

The roof rack didn't survive. Well it did but the rack, spare tire and lights all landed separate from the truck. And none of the guys got any pics or video.
I'm thinking the only way for me to fix this and prevent it from happening again is to pull the head liner and use some through bolts and large washers. But I don't know a thing about pulling the headliner.
How do I got about pulling the headliner? Unless somebody has a better suggestion.

 

[MOBmentality]

Cut out the inserts... weld in filler plates.. sand smooth.. rattle can some rust prohibiter.. then do a vinyl roof skin... = FTW

 

[07Burb]

Cut out the inserts... weld in filler plates.. sand smooth.. rattle can some rust prohibiter.. then do a vinyl roof skin... = FTW

couldn't have said it better myself!

 

[T-Bagg]

I considered a vinyl roof since it would match my Caddy. But I use that rack. For the spare, my lights and gas cans, sometimes firewood. Plus, I lose some of my trucks off road cred. Gotta keep the cool factor.

 

[SunlitComet]

put large rectangular plates inside cab. weld them to cab for structural support and drill them for the racks.

The head liner should have some clips holing it up to the structure.

 

[Done Deal DR]

I currently have my headliner out, it was held in by several bolts... many of them integrated into the grab handles.

 

[sumo]

Cut out the inserts... weld in filler plates.. sand smooth.. rattle can some rust prohibiter.. then do a vinyl roof skin... = FTW

Umm my thoughts exactly?

 

[T-Bagg]

Me and a buddy of mine, we're talking about patching the holes and then welding the rack directly to the roof.

 

[07Burb]

That might work too. Only issue is next time it might destroy the whole roof when you decide to jump the rig again depending on how much weight is up there....

 

[96ProCompTahoe]

ExoFrame FTW! (have always wondered how strong those mounts really are)

 

[SunlitComet]

I currently have my headliner out, it was held in by several bolts... many of them integrated into the grab handles.

Bolts it is then. Sorry. Thought I saw clips on mine a month ago.

 

[19Yukon97]

Sunlitcomet- I think the rear of the headliner is held on by clips. atleast mine was like that when i was putting my new speakers and running wires up there. the front its held on bythe grab handle bolts and the roof console if you have one.

 

[bowtiefreak]

put large rectangular plates inside cab. weld them to cabfor structural support and drill them for the racks.

this

 

[SunlitComet]

Actually I now recall that there were screws as well. I forgot the sun visors were screwed thru the head liners plus something else. Oh well.

 

[raptorforme93]

this

Hahaha. I love the response

 

[T-Bagg]

I pulled the rear of the headliner(held up by bolts in the grab handles and the trim in the rear) and there is a metal plate that covers those receptacles from the inside. I was going to run bolts all the way through and put fender washers and nuts on the inside, securing the washer and nut to the roof with J-B Weld if I ever want to pull the rack off again. Those plates cancelled that.
So, instead, I'm going to put the stock receptacles/nuts back into the roof. With a little J-B Weld around the rim and tap the metal back into place to hold it. I'm also putting a lite coat of J-B Weld around the holes to reinforce the cracks there.
I'm no longer going to carry the spare up there. Because I think it was the weight of that on top of the Hi-Lift that pulled the rack off in the jump. As I'm sure that exceeded the hundred pound weight limit up there.

 

[T-Bagg]

Finally fixed the roof rack. My JB Weld solution did not work. it failed almost immediately. How I fixed it.
Removed the headliner to access the underside of the roof.

The headliner was held in by, moving from back to front: Plastic trim, Bolts through the hooks and grab handles, back seat belt bolts(I couldn't get any tools on these, the window would have to come out so I cut the trim and slid it around the bolt. barely noticeable), trim that runs up the B-pillar(clipped in), front seat belt bolts(torx bits), bolts through the grab handles above the passenger door and A-pillar, trim over the doors(handles hold these on plus clips), screws holding the sun visors up, the over head console(fastened by one screw at the front) and the cabin lights(pop the light cover off and two screws underneath).
The roof rack receptacles are hidden behind some steel.
Here in the back,

And here in the front,

The old receptacles were broken free so I just pulled those out the top. To be replaced with these,

Different lengths of 1/4 in socket head bolts, fender washers and nylon locking nuts.
To gain access to thread the washer and nut onto the bolt. Holes had to be drilled through the steel.

In the back, the hole on the left(back) was already there but had to be filed open to allow a 7/16 socket. the other had to be drilled. I stuck the bolts through from the roof. Placed the washers over the new holes with some serious finger ******* and using long skinny tools(a file) to push them around.

I put the 7/16 nut into the socket and on the end of an extension. I pushed the socket through the hole and balanced the washer on it as I pressed them onto the bolt threads. This required patience.

The front, the hole on the right(front) was there, unfortunately those were the only receptacles not to break. The other hole had to be drilled and filled open to allow a socket. The front was significantly easier than the back as I could use my skinny ass fingers to put the washers on the bolts and then the socket and extension to install the nut.
Tightened everything down and then re-installed the headliner.
Hope this helps anyone else who breaks their rack off or just wants to strengthen up their rack a little.

 

[jd08]

Looks good but did you seal up around the bolts at all so no water leaks in?

 

[SunlitComet]

 

[96ProCompTahoe]

that looks like it was a pain in the ass! rethinking the roof rack i had planned for the 'hoe as im starting to think it won't be solid enough for the $ and trouble.