Wagon Roof Rail Removal - Page 3
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This is a discussion on Wagon Roof Rail Removal within the Exterior and Appearance forums, part of the Tutorials & DIY category; Here is a letter I recieved from an inquiy into 04 roof rail removal...I was told to order extra clips... ...

  1. #31
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    Here is a letter I recieved from an inquiy into 04 roof rail removal...I was told to order extra clips... Just in case

    I will do this in august.

    Below is a list of all the parts you would need in order to remove your
    roof rails, all of these parts are special order and would take about 1
    week to get in. If you would like to order theese parts we would need for
    you to pay in advance.
    91046FE000 MOULDING = $68.58
    91046FE010 MOULDING = $68.58
    909130022 CLIP = $2.37 each qty required = 14
    909300044 CAP = $1.77 each qty reguired = 2
    909130021 CLIP = $2.37 each qty reguired = 6
    909130069 CLIP = $3.71 each qty required = 1
    909130064 CLIP = $3.71 each qty required = 1

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  3. #32
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    little bit o' info.

    I took mine off last Thursday night. The most difficult part is taking the "oh ****" handle molding off without using a tool. But, a word of warning to the stupid people like me!

    Do not over tighten the bolts that hold the handles to the frame up front! had to drill a hole in the busted bolt and use a screw extractor... the bolts are especially weak as they appear to be somewhat self tapping... dunno, but that have some cuts in them that act as stress concentrations.

    Looks great without those rails, and now I can use a normal yakima Q-tower setup back there.

    edit to add:
    I REUSED ALL MY CLIPS TOO!
    just pull the front of the little front portion and then slide off. and the big rearward portion you can just carefully slide off the clips. dang, i wish I'd taken pics...

  4. #33
    Moderating on the run! Big Sky WRX's Avatar
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    Thanks for the tips!

    One uestion still in my mind is the "expansion" bolts/nuts- what do these look like? I'm having a hard time envisioning these.

    Thanks

    Mike

  5. #34
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    Originally posted by Big Sky WRX

    One uestion still in my mind is the "expansion" bolts/nuts- what do these look like? I'm having a hard time envisioning these.
    [/B]
    Do you live near a home depot? It's pretty easy to get 'em there.

    Here's a picture (disregard the size called out in the pic. I found these real quick online...):


    don't forget the screws and washers also.

    However, the frontmost holes are all oblong, yet the two rearmost holes are circular and smaller. I took a different approach then others here. While some people drill these last holes larger to fit the expansion nuts, I simply used some #10-24 SS machine screws and nuts and made big rubber washers with an old bike tube. It worked great, sealed the hole, and didn't involve drillling. I'd probably use this method for all the holes if I were to do it again... I wasn't impressed with those expansion nuts.

    You riding in an 04 wagon now?

  6. #35
    Moderating on the run! Big Sky WRX's Avatar
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    OK- thanks. I do have a home depot relatively close (close for MT anyways- 140 miles ).

    Yup I've got a new pony- 04 wagon

    Big Sky

  7. #36
    Registered User Quack's Avatar
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    Originally posted by Balthus
    Here is a letter I recieved from an inquiy into 04 roof rail removal...I was told to order extra clips... Just in case

    I will do this in august.

    Below is a list of all the parts you would need in order to remove your
    roof rails, all of these parts are special order and would take about 1
    week to get in. If you would like to order theese parts we would need for
    you to pay in advance.
    91046FE000 MOULDING = $68.58
    91046FE010 MOULDING = $68.58
    909130022 CLIP = $2.37 each qty required = 14
    909300044 CAP = $1.77 each qty reguired = 2
    909130021 CLIP = $2.37 each qty reguired = 6
    909130069 CLIP = $3.71 each qty required = 1
    909130064 CLIP = $3.71 each qty required = 1
    the parts for the molding are what i used. i didn't get any extra clips.

    if you can't find the plugs the silicone route works too. no leaks in the ~2 months that i've had the rails off.

  8. #37
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    Yep, I think I pulled the numbers from one of your ealier post's. I have been going back and forth about doing this, but I am commited now...

    Wagons rule!

  9. #38
    Moderating on the run! Big Sky WRX's Avatar
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    I got the mouldings from my dealer (ordered today!)- freight was a little pricey on line- he gave me a good deal at $56 each.

    Hopefully I won't break any of the clips when doing this- after three years I'm just starting to master the many plastic clips Subaru uses

    A dab of silicone on each one sounds like a good plan.

    Mike

  10. #39
    Registered User Quack's Avatar
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    with the silicone, back the holes with duct tape and filler up until it over-flows a little...

    Last edited by Quack; 06-28-2004 at 09:54 PM.

  11. #40
    Moderating on the run! Big Sky WRX's Avatar
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    That looks nice!

  12. #41
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    I started to remove them today, then realized I'd have to take out the headliner to get to the mounting brackets.... So I'll probably do it tomorrow...

    Anyone think of filling the rails with bondo, or filler, and painting it OEM? might look pretty cool... just an idea... More than 100 bucks for 2 pieces of weatherstripping is ridiculous...

    3-M makes the best weatherstripping in a can, like silicone... And weatherstripping adhesive...

    I know you can buy random sizes of straight weatherstrip from Autozone, anyone try it?

  13. #42
    Registered User Quack's Avatar
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    it's not weather-stripping, it's just a trim piece.
    i would think that if you fill it with bondo, it may eventually crack.

    here's a pic of the finished trim.
    Last edited by Quack; 12-09-2005 at 01:23 PM.

  14. #43
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    I agree with Quack... Plus it's a pretty deep groove. Just get the pieces. I bet you'll be glad you did.

  15. #44
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    Glad to see the post is still alive. It has been 2.5+ years since I did mine with NO leaks what so ever. It's too bad that SOA doesn't offer a delete option.

    Keep up the great work guys.

    Russell
    Russell
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    12.9 @ 105 MPH (4EAT)

  16. #45
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    holy cow, you started this back on 11-05-2001

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