Roof Racks/Branch Guard on Total Composite Box?

[fjefman]

How are these mounted to the roof? The extrusion pieces on the perimeter of the box are hollow so I assume they are not mounted there, so how does one mount them? Can't find many examples of these on DIY boxes.

 

[mog]

How are these mounted to the roof? The extrusion pieces on the perimeter of the box are hollow so I assume they are not mounted there, so how does one mount them? Can't find many examples of these on DIY boxes.

While certainly not 'approved' or 'measurable by engineering standards' while helping to assemble a Total Composite box myself and others were debating if 'filling' the hollow section would make them stronger. I took a 2 pound sledge hammer to a spare section and 'beat the living heck out of it' with nothing happening other than the hammer just bouncing off and all of us being quite impressed. I would say not recommended for other than 'spare' sections, but I was very impacted by the results.

It case you are not up on the current Total Composite situation, these are no longer 'DIY'. They do not sell kits to individuals, with all of their 'assembled' product available through their network of approved shops. You can order a custom box to your size and design, but that is via the builder/vendor. You can find their list of approved builders/vendors here- https://totalcomposites.com/purchase-truck-camper/

If you have general questions, or need help finding a builder @Victorian is active on this forum, is very helpful, super knowledgeable, and an all round great guy.

Disclaimer - I have NO relationship with Total Composite Technologies Ltd. & Expedition Upfitter other than using their products. All opinions (and testing methods 😉 ) are my own, based on my experiences.

 

[andy_b]

How are these mounted to the roof? The extrusion pieces on the perimeter of the box are hollow so I assume they are not mounted there, so how does one mount them? Can't find many examples of these on DIY boxes.

They are commonly rivnutted and maybe glued. As @mog mentioned, the extrusions are strong and the job of these rails are to act as branch deflectors and/or a final reminder that you’re about to do something you’ll regret on a tight trail or parking structure.

 

[fjefman]

While certainly not 'approved' or 'measurable by engineering standards' while helping to assemble a Total Composite box myself and others were debating if 'filling' the hollow section would make them stronger. I took a 2 pound sledge hammer to a spare section and 'beat the living heck out of it' with nothing happening other than the hammer just bouncing off and all of us being quite impressed. I would say not recommended for other than 'spare' sections, but I was very impacted by the results.

Yes, I’m aware of no DIY from TC but even if I use their panels and have someone put it together the rub rails will likely be DIY so just curious how it all goes together.

I’ve never touched an extrusion so I had no idea they were as strong as you describe. Still, if they are a key part of the structure, and part of the wire run i’m not sure I’d want to drill into them.

I might be overthinking the need for rub rails but I do like the idea of them. I’m sure reality will set in hard once I’ve actually starting putting $ down on my build.

 

[fjefman]

They are commonly rivnutted and maybe glued. As @mog mentioned, the extrusions are strong and the job of these rails are to act as branch deflectors and/or a final reminder that you’re about to do something you’ll regret on a tight trail or parking structure.

Are you saying that the extruded rails do a good enough job that I don’t need anything additional?

 

[andy_b]

Are you saying that the extruded rails do a good enough job that I don’t need anything additional?

It depends on what you need the rails to do. You don’t need the rails at all. IDK if they actually add anything apart from looking cool. I don’t have any on mine.

 

[Victorian]

Sorry for the delay in a response from us…. I just got back from putting our brush guards through a nice work out on Vancouver Island
We have seen several variations of brush guards from our customers over the years. All serve the purpose of protecting the the camper/solar system/roof hatch from hard impacts through branches. We recommend using adhesive to mount them. This will allow the fiberglass and the metal guards to expand/contract according to the the material properties without creating tension. Screws/rivets etc would ad potential points for water to enter…
Because our campers are standardized you could reach out to OffGrid Customs in Squamish BC and see if they sell you a set. https://offgridcustoms.com/off-grid-campers-1/

 

[charlieaarons]

This is what Unicat added to my roof before trip to Africa. And it’s a good thing they did, there’s a 72km totally overgrown truck in Central Kalahari Game Reserve from Xade Entrance to Piper Pan that would have removed solar panels.
They seem to be L pieces that are mounted flush to the roof.
Glued? They recommend against penetrations of the roof.
Note the scupper holes.
They worked.

 

[fjefman]

Yeah, I'm thinking more for protection of the fan and solar panels than anything else. I certainly won't be wheeling my rig, but even the forest service roads can be pretty crowded with trees here in the SouthEastern U.S.

@Victorian do you recommend the panels are glued to the panels themselves, or to the Extrusions?

 

[Victorian]

Yeah, I'm thinking more for protection of the fan and solar panels than anything else. I certainly won't be wheeling my rig, but even the forest service roads can be pretty crowded with trees here in the SouthEastern U.S.

@Victorian do you recommend the panels are glued to the panels themselves, or to the Extrusions?

The FRP pultrusions would be prefect as the glue surface. Here is a link to the instructions: total_composites_accessory_bracket_install_guide.pdf