Register Login
Save up to 15% with Adrian Flux insurance!
Reply
 
Thread Tools
Old 14-11-2012   #1
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Roof rails on hi-roof DoblÚ

I've been reading various threads about fitting aftermarket roof rails to the dobbie, but can't find anything related to the hi-roof version.

On this model the roof will have to be drilled in order to fit roof rails, as on the top of the roof four small recessed areas for fitting the rails are present but there are no holes.

I am aware of at least one forum member's mod to fit roof rails to the hi-roof model, so I'd appreciate any pointer and comments to the right direction!

Thanks in advance!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 14-11-2012   #2
Join Date: May 2011
Location: West Wales
Posts: 158
Thanks: 7
Trader Rating: 0
Poperon has donated!
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Hi,

Had the same about a year ago.

Couldnít find any roof rails off the peg so went to the local breakers yard for some inspiration.

Landed up taking the rails off an R reg Volvo 960 Estate (940 ones are identical). Aluminium, well made and £20.

They are too long to fit straight onto a DoblÚ high top and need a bit of modding to get them to fit (shortening and gently bending to fit the curve of the roof). Took a bit of time but it is doable.

Fixing to the roof is mostly the same as the fixing method on the Volvo.

Each of the 3 mounting feet is bolted to the roof cross member (these run across the roof underneath the recesses in the DoblÚ roof) with an M5 socket headed bolt which passes through an M10 threaded tube (5.5mm bore) which is screwed into an M10 Rivnut in the roof.

The mounting method seems a bit involved but itís designed to transmit the load from the roof rail foot onto the roof cross members (not solely onto the roof!) without deforming the roof itself. The threaded tubes are screwed out just enough to fill the gap between the rivnut and the cross member.

The joint between the roof rail and roof is sealed with some 5mm thick closed cell foam; the correct gap is maintained by the 2mm thick flange of the Rivnut.

It took about a morning+ to do, but I think itís worth it.

Cheers

Ron




Thanks TD5 thanked for this post
Likes TD5 liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Poperon is offline Reply With Quote Quote 
Old 14-11-2012   #3
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Excellent writeup Ron!!!

Nicely complemented by your scheme and pic!

Would it be possible to make tag or maybe make a sticky? The above info is going to useful to others no doubt.

I have a question (possibly more I can't think of just now :-D ):

- how difficult/fiddly is to remove the ceiling cover trim and to put it back correctly?

Again thanks so much
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 14-11-2012   #4
Join Date: May 2011
Location: West Wales
Posts: 158
Thanks: 7
Trader Rating: 0
Poperon has donated!
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Hi,

HmmmmÖRemoving the ceiling lining; well we planned to take it down to add some insulation and a vapour barrier and whilst it was down do the roof rails at the same time.

The main problem was the fixings; they are quite difficult to get out without either breaking them off or damaging the lining material. Replacements seem hard to find.

Solution wasÖ the ďRivnutĒ (what an invention!!).

Once the original fixings are out (whole or broken off) fix an M4 rivnut in the 6.5mm hole in the bodywork where the original ceiling fixing would have gone. Re-fix the ceiling with M4 15mm long bolts/screws using a large colour matched screw cup and cover (from eBay).

The M4 bolt holds the lining up and the screw cap covers the holes in the lining well enough (bit more discreet than the factory fitted ones). Also, easily removable in the future.

Cheers

Ron
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Poperon is offline Reply With Quote Quote 
Old 14-11-2012   #5
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Genius!

Well a rivnut fastener is already on my list of tools to get ASAP then!

Cheers :-))))
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 15-11-2012   #6
Join Date: May 2011
Location: West Wales
Posts: 158
Thanks: 7
Trader Rating: 0
Poperon has donated!
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Iíve got a small Rivnut tool (Silverline I think, about a tenner). Itíll do up to M8 Ok but if you need to use a lot of larger ones (like the M10 for the roof rail mod) a heavier duty tool is the one to get.

For the M10 Rivnuts (with only 6 to do) I found a design for home made tool on the web, which isnít much more than a bolt and a few nuts and washers. It works well and only cost a couple of quid.

Good luck

Ron
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Poperon is offline Reply With Quote Quote 
Old 15-11-2012   #7
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Agreed, a diy version of the rivnut fastener is the way to go for m10 rivnuts (unless having to do lots of them) as proper tools are expensive - was chatting with a friend last night and he uses a heavy duty one at work (no, he won't be able to let me use it...) and he reckons a home made tool would be much better than any cheap tool out there - unless I wanted to splash out the money for a proper one - not!

Ron, did you use M10 steel or aluminium rivnuts?

Trip to local scrapyard due soon!!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 15-11-2012   #8
Join Date: May 2011
Location: West Wales
Posts: 158
Thanks: 7
Trader Rating: 0
Poperon has donated!
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Yea, I canít abide cheap tools but the pukka rivnut tools were a bit on the pricey side; thought Iíd try the Silverline one (got OK reviews on Amazon) and for its money has done well and put in a couple of hundred rivnuts without falling apart.

I used the plated steel rivnuts with a 2mm thick flange (same as Volvo used) from Memfast and smeared everything with Waxoyl during assembly. The rivnuts left in the roof of the 960 in the breakers yard were still in newish condition, the closed cell foam should seal out any water. No leaks at all.

I expect the Aluminium ones would be Ok, I just bowed to Volvoís judgement!

Cheers

Ron
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Poperon is offline Reply With Quote Quote 
Old 15-11-2012   #9
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Aye, can't go wrong with Volvo's way!

The waxoyl would probably be enough to seal everything, but the closed cell foam is definitely a must, plus it gives a professional finish.

You've done an amazing job Ron, kudos!!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 15-11-2012   #10
Join Date: May 2011
Location: West Wales
Posts: 158
Thanks: 7
Trader Rating: 0
Poperon has donated!
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Hi Bidello,

If you do find a pair of roof rails on a scrap Volvo and you take them off yourself then the fixing method will become clear.

To get them to fit on your Doblo the end feet need to removed from the rails and then the rails need to be shortened off and with a bit of gentle bending the feet sit snugly in the recesses in roof.

The feet are connected to the rail by a spigot (part of the foot casing) which fits into the ends of the rail, itís bonded in place with a gap filling adhesive.

I found the best way to remove it was to cross cut the rail just clear of the spigot end (about 40mm in if I remember). Check you arenít cutting too much off leaving the rail short! Carefully cut along the scrap length of rail left on the foot spigot (without cutting too much into the spigot) and peel/lever it away from the spigot assisted by something like a largish slotted screwdriver.

Once off the old glue will chip off the spigot and the job of gradually curving the rail (soft jaws in a vice to hold it without damage to the paintwork) and incrementally cutting the rail to length can commence.

Next job is to drill the holes in the roof, fix rivnut etc.(Scary bit)

Dry run the modded rail on the roof and if all fits well take apart and smear suitable adhesive over each spigot and in the ends of the rails, reassemble in place and allow adhesive to set.

Thatís about it. Load up!

Cheers

Ron
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Poperon is offline Reply With Quote Quote 
Old 16-11-2012   #11
Join Date: Jul 2011
Location: Essex
Posts: 212
Thanks: 19
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Just a quick comment to say that I think those bars look excellent. Great lateral thinking Poperon
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides


Last edited by Yobbo; 16-11-2012 at 01:27.
Yobbo is offline Reply With Quote Quote 
Old 21-11-2012   #12
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

OK, first update:

Been to a local scrapyard, no Volvos 940/960

However, I did find some Fords roof rail

They did look nice, spigots on the feet that fit into the rails by means of a rubber gasket, no glue to be removed....

Bad point was that each foot had a bold embedded in the aluminium, too short to fit on the DoblÚ

So didn't get them. Shame, they wanted only £15.

Had a look on the auction site and some are asking £80

Will find them no doubt at some point
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 02-04-2013   #13
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Hi all,

It took me a while to find the right rails for the mod and even more time to fit them...but it's done at last!

I started taking picture to aid others in the process, but then it started to snow so hard that I had to stop Fortunately I had put only one rivnut on so I sealed the hole and waited for next day - more snow....

Anyway I then finished the whole thing last weekend, but never took any other picture

I will take one last pic of the finished work, although it is not needed as you can see the nice picture of Poperon's DoblÚ above.

Also, please note that my pictures are only intended to be a visual aid to the excellent step-by-step Poperon guide, stick to it and you'll end up with a nice railed high-roof DoblÚ

Cheers
Attached Thumbnails
Click image for larger version

Name:	IMG_2026.jpg
Views:	32
Size:	3.17 MB
ID:	114977   Click image for larger version

Name:	IMG_2027.jpg
Views:	26
Size:	2.33 MB
ID:	114978  

Click image for larger version

Name:	IMG_2029.jpg
Views:	21
Size:	2.51 MB
ID:	114979   Click image for larger version

Name:	IMG_2031.jpg
Views:	22
Size:	2.72 MB
ID:	114980  

Click image for larger version

Name:	IMG_2033.jpg
Views:	14
Size:	2.69 MB
ID:	114981   Click image for larger version

Name:	IMG_2034.jpg
Views:	19
Size:	2.08 MB
ID:	114982  

__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Old 02-04-2013   #14
Join Date: May 2011
Location: West Wales
Posts: 158
Thanks: 7
Trader Rating: 0
Poperon has donated!
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Wow..that all looks great.....there's only one drawback, you need to take a set of steps with you to load up ...unless of course you're 7'+ !!

Cheers

Ron
__________________
2006 Doblo 1.9 Multijet Dynamic. High Top. Blue Teseo. Camper.
Poperon is offline Reply With Quote Quote 
Old 05-04-2013   #15
Join Date: Nov 2012
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Roof rails on hi-roof DoblÚ

Yeah, quite right! I'm buying a foldable step/ladder to access the roof!

I'm also fitting a narrow, long roofbox to carry my gear, so I have the other half of the roofbars free for my longboard

Will take pics ASAP.

Thanks again for all your help Poperon, very much appreciated
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Bidello is offline Reply With Quote Quote 
Reply
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Thread Thread Starter Forum Replies Last Post
(G) Doblo Roof rails Fiattastic Doblo 4 17-01-2011 18:07
(S) doblo roof rails derbydoblo Doblo 2 20-01-2009 18:59
(S) Doblo Roof Rails Mackers Doblo 6 25-09-2006 14:54
(S) roof rails for doblo gww Doblo 1 07-02-2006 21:25