Roof rails, mounting instructions
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-
- Started learning about 480
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- Joined: Sat Nov 06, 2021 10:45 pm
Roof rails, mounting instructions
hello again,
does anyone have mounting instructions for the original roof rails?
does anyone have mounting instructions for the original roof rails?
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
- jamescarruthers
- 480 Is my middle name
- Posts: 2515
- Joined: Mon Jul 07, 2003 3:19 pm
- Location: Cambridge
Re: Roof rails, mounting instructions
Other than this picture from the parts book, I don’t have anything. They really are screwed in to the roof though! Definitely a one-time installation!
You can download the parts book here:
http://volvo480.myds.me/v480eu/download ... tsbook.pdf
You can download the parts book here:
http://volvo480.myds.me/v480eu/download ... tsbook.pdf
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
- jamescarruthers
- 480 Is my middle name
- Posts: 2515
- Joined: Mon Jul 07, 2003 3:19 pm
- Location: Cambridge
Re: Roof rails, mounting instructions
There was a set for sale recently, sadly broken. For more pictures, see the eBay listing:
https://www.ebay.co.uk/itm/Genuine-volv ... 635-2958-0
It looks like the roof is drilled, Riv-nuts are installed, then the mounting rail is screwed to the roof with a rubber gasket inbetween. It screams rusty-roof to me although I did see one in Scotland once and it seemed to have survived up there.
https://www.ebay.co.uk/itm/Genuine-volv ... 635-2958-0
It looks like the roof is drilled, Riv-nuts are installed, then the mounting rail is screwed to the roof with a rubber gasket inbetween. It screams rusty-roof to me although I did see one in Scotland once and it seemed to have survived up there.
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
Re: Roof rails, mounting instructions
OK, I own up, I bought those .jamescarruthers wrote: ↑Tue Nov 23, 2021 10:09 pmThere was a set for sale recently, sadly broken. For more pictures, see the eBay listing:
https://www.ebay.co.uk/itm/Genuine-volv ... 635-2958-0
It looks like the roof is drilled, Riv-nuts are installed, then the mounting rail is screwed to the roof with a rubber gasket inbetween. It screams rusty-roof to me although I did see one in Scotland once and it seemed to have survived up there.
Although it stated that one of the end clips was broken, I noticed there were 5 in the photos, so wondered if someone had already bought a replacement... I have yet to actually see it all in person since I got my father-in-law (they live near Southampton) to collect it and we're not seeing them until Christmas. Whether or not it is complete, and whether or not I fit it to one of the cars, both remain to be seen, but for the deal I struck it was worth chancing it!
But as far as I know there are no instructions - if there are, I will of course make them available.
David
Current: 1994 480 GT, 1996 460 CD & 1997 440 LE with lots of optional extras & 2007 V50 SE Sport
Previous: Celebration 331 (re-homed with Richard S), Celebration 467 (returned to Martin Mc); Celebration 346 (re-homed with Alan480); Celebration 269 (scrapped abandoned project), Celebration 73 (sold on after 6 years), 1992 ES, 1988 ES - and numerous other non-480 Volvos!
Previous: Celebration 331 (re-homed with Richard S), Celebration 467 (returned to Martin Mc); Celebration 346 (re-homed with Alan480); Celebration 269 (scrapped abandoned project), Celebration 73 (sold on after 6 years), 1992 ES, 1988 ES - and numerous other non-480 Volvos!
- jamescarruthers
- 480 Is my middle name
- Posts: 2515
- Joined: Mon Jul 07, 2003 3:19 pm
- Location: Cambridge
Re: Roof rails, mounting instructions
To avoid corrosion issues, I would recommend an interfay sealant between the roof and the rubber and the rubber and the rails. NOT RTV silicone!
I may be able to supply you with some mega aircraft stuff (PS870) when the time comes to install as we have stuff that goes out of date but is okay for a few months afterwards. If not, something like Sikaflex marine sealant would do as an alternative.
If you don’t have a Rivnut installation tool already, Car Builder Solutions will sell you one.
https://www.carbuilder.com/uk/search?q=Rivnut
I’m sure you know to prime and paint the holes in the roof for the Rivnuts but I’d also recommend to install these wet with the sealant too and then install the bolts wet too.
I may be able to supply you with some mega aircraft stuff (PS870) when the time comes to install as we have stuff that goes out of date but is okay for a few months afterwards. If not, something like Sikaflex marine sealant would do as an alternative.
If you don’t have a Rivnut installation tool already, Car Builder Solutions will sell you one.
https://www.carbuilder.com/uk/search?q=Rivnut
I’m sure you know to prime and paint the holes in the roof for the Rivnuts but I’d also recommend to install these wet with the sealant too and then install the bolts wet too.
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
Re: Roof rails, mounting instructions
Thank you James, that's all helpful stuff!jamescarruthers wrote: ↑Wed Nov 24, 2021 10:12 amTo avoid corrosion issues, I would recommend an interfay sealant between the roof and the rubber and the rubber and the rails. NOT RTV silicone!
I may be able to supply you with some mega aircraft stuff (PS870) when the time comes to install as we have stuff that goes out of date but is okay for a few months afterwards. If not, something like Sikaflex marine sealant would do as an alternative.
If you don’t have a Rivnut installation tool already, Car Builder Solutions will sell you one.
https://www.carbuilder.com/uk/search?q=Rivnut
I’m sure you know to prime and paint the holes in the roof for the Rivnuts but I’d also recommend to install these wet with the sealant too and then install the bolts wet too.
Don't worry, I wouldn't go anywhere near a car with silicone sealant
It's the need to go drilling through the roof that bothers me, and if I do fit the system I am very aware of the need to get that right. As you mention, I was already thinking about speaking with father-in-law since they own a rather nice boat and he's quite an expert in maintenance etc. I hadn't thought about aircraft stuff though...
As for the tips on actually doing the fitting, your advice is gratefully received
David
Current: 1994 480 GT, 1996 460 CD & 1997 440 LE with lots of optional extras & 2007 V50 SE Sport
Previous: Celebration 331 (re-homed with Richard S), Celebration 467 (returned to Martin Mc); Celebration 346 (re-homed with Alan480); Celebration 269 (scrapped abandoned project), Celebration 73 (sold on after 6 years), 1992 ES, 1988 ES - and numerous other non-480 Volvos!
Previous: Celebration 331 (re-homed with Richard S), Celebration 467 (returned to Martin Mc); Celebration 346 (re-homed with Alan480); Celebration 269 (scrapped abandoned project), Celebration 73 (sold on after 6 years), 1992 ES, 1988 ES - and numerous other non-480 Volvos!
- jamescarruthers
- 480 Is my middle name
- Posts: 2515
- Joined: Mon Jul 07, 2003 3:19 pm
- Location: Cambridge
Re: Roof rails, mounting instructions
No problem: I'm sure you'll be fine, just get it nicely aligned. I may have some skin pins that i could send you to make sure it all stays aligned while drilling-- proper clamping should be sufficient though.
Basically:
-drill the hole (hole size will be critical for rivnuts so this will need researched);
-deburr it (a drill bit more than double the hole size will be sufficient if you don't have the correct tool-- drill bits are cut at 90 degs so will do the same work)
-prime it and allow drying time
-top coat it and allow drying time (optional)
-put a tiny bit of sealant on the Rivnut shank and install it, then clean up (no need to wait for it to cure)
-trial fit the rails and rubber
-apply masking tape around periphery
-apply thin layer of sealant to roof and rails
-lay on rubber gasket
-put tiny amount of sealant on to threads and shank of bolts
-install rails, taking care not to overtorque bolts going in to Rivnuts (you don't want them to spin)
-clean up
You could consider nuts and bolts instead of the Rivnuts but obviously you have the hassle of removing the headlining then.
Basically:
-drill the hole (hole size will be critical for rivnuts so this will need researched);
-deburr it (a drill bit more than double the hole size will be sufficient if you don't have the correct tool-- drill bits are cut at 90 degs so will do the same work)
-prime it and allow drying time
-top coat it and allow drying time (optional)
-put a tiny bit of sealant on the Rivnut shank and install it, then clean up (no need to wait for it to cure)
-trial fit the rails and rubber
-apply masking tape around periphery
-apply thin layer of sealant to roof and rails
-lay on rubber gasket
-put tiny amount of sealant on to threads and shank of bolts
-install rails, taking care not to overtorque bolts going in to Rivnuts (you don't want them to spin)
-clean up
You could consider nuts and bolts instead of the Rivnuts but obviously you have the hassle of removing the headlining then.
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
These are good tips, thank you.
Do you think if I use threaded rivet to fix the rails I do not need to remove the headlining - I'm a little afraid of removing that.
The topic of sealing and corrusion is really critical. What do you think of neoprene threaded rivets ?
https://vimeo.com/400550041
Do you think if I use threaded rivet to fix the rails I do not need to remove the headlining - I'm a little afraid of removing that.
The topic of sealing and corrusion is really critical. What do you think of neoprene threaded rivets ?
https://vimeo.com/400550041
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
- jamescarruthers
- 480 Is my middle name
- Posts: 2515
- Joined: Mon Jul 07, 2003 3:19 pm
- Location: Cambridge
Re: Roof rails, mounting instructions
Nice roof rack set!
You won’t have to remove the headliner, that’s the whole point of the Rivnut in this application. A bit of drill swarf will get trapped between it and the roof but don’t worry about it. You should have seen how much rusty metal was trapped in mine from the crappy Volvo dealer sunroof installed in 1987! If you do feel the need to remove the roof liner, then I just wouldn’t bother with the Rivnuts at all— they are just a time saver— I’d just go straight for nuts and bolts.
I would advise against the Neoprene rivnuts as I would suspect that they probably can’t take the forces of a loaded rack and could pull out. They would be better for a less structural application. I’m happy to be proven wrong on this if you compare the specification sheets of the Aluminium and Stainless ones but this is my gut feeling.
Use the Aluminium Rivnuts with sealant and you will be fine. If anything does corrode, it should be the Aluminium, not the steel. (For this same reason, do not be tempted to install Stainless Steel ones— the roof will corrode in preference to the Stainless!).
Thinking out loud: once the rails are installed, they are installed for good and you have holes in your steel roof. What is to stop you just installing the rails with pop rivets anyway— again, installed wet with sealant on the shanks and also in the hole for the pulling tail? I suppose water could get through the hole in the middle if you don’t do a good job?
You won’t have to remove the headliner, that’s the whole point of the Rivnut in this application. A bit of drill swarf will get trapped between it and the roof but don’t worry about it. You should have seen how much rusty metal was trapped in mine from the crappy Volvo dealer sunroof installed in 1987! If you do feel the need to remove the roof liner, then I just wouldn’t bother with the Rivnuts at all— they are just a time saver— I’d just go straight for nuts and bolts.
I would advise against the Neoprene rivnuts as I would suspect that they probably can’t take the forces of a loaded rack and could pull out. They would be better for a less structural application. I’m happy to be proven wrong on this if you compare the specification sheets of the Aluminium and Stainless ones but this is my gut feeling.
Use the Aluminium Rivnuts with sealant and you will be fine. If anything does corrode, it should be the Aluminium, not the steel. (For this same reason, do not be tempted to install Stainless Steel ones— the roof will corrode in preference to the Stainless!).
Thinking out loud: once the rails are installed, they are installed for good and you have holes in your steel roof. What is to stop you just installing the rails with pop rivets anyway— again, installed wet with sealant on the shanks and also in the hole for the pulling tail? I suppose water could get through the hole in the middle if you don’t do a good job?
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)
Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)
- dragonflyjewels
- 480 Is my middle name
- Posts: 1595
- Joined: Sat Dec 18, 2010 10:38 am
- Location: Norfolk
Re: Roof rails, mounting instructions
Rescue car R4 has the roof rails, plus associated rust. If it helps I can take photos/measurements so you can get the placement right. This one came from Switzerland, one owner from new and always Volvo serviced so I'd be very surprised if they weren't fitted by Volvo
Sylvia
Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo
Paris the Unicorn - 1991 Paris Edition
hubby has
Sven - 1994 Racing Green GT
Evil Eva - 1992 Paris Blue Turbo
no previous 480s - can't bear to sell any
Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo
Paris the Unicorn - 1991 Paris Edition
hubby has
Sven - 1994 Racing Green GT
Evil Eva - 1992 Paris Blue Turbo
no previous 480s - can't bear to sell any
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
Would be perfect to get some measurements where the rails should be fixed precisely.
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
- dragonflyjewels
- 480 Is my middle name
- Posts: 1595
- Joined: Sat Dec 18, 2010 10:38 am
- Location: Norfolk
Re: Roof rails, mounting instructions
Here we are:
Pic 1 - Distance back from the windscreen. With the touch point at 30mm, it's 73mm by my eyes. Always tricky to measure a curve with a straight rule but I don't trust the end sliders on tape rules.
Pic 2 - At the front there's a few mil between the start of the roof's downward side curve and the rail
Pic 3 - the moonroof is on the left and the rail on the right. At the centre of the moonroof, there is 30mm between the rail and moonroof rubber. The other side of the rail is more or less dead on the edge of the roof at this point - it feels flush with the vertical line where the roof curves down.
Pic 4 - Assuming the rails are the right ones, this is the gap you should have at the back.
Hope this helps - just shout if I've managed to cause confusion.
Pic 1 - Distance back from the windscreen. With the touch point at 30mm, it's 73mm by my eyes. Always tricky to measure a curve with a straight rule but I don't trust the end sliders on tape rules.
Pic 2 - At the front there's a few mil between the start of the roof's downward side curve and the rail
Pic 3 - the moonroof is on the left and the rail on the right. At the centre of the moonroof, there is 30mm between the rail and moonroof rubber. The other side of the rail is more or less dead on the edge of the roof at this point - it feels flush with the vertical line where the roof curves down.
Pic 4 - Assuming the rails are the right ones, this is the gap you should have at the back.
Hope this helps - just shout if I've managed to cause confusion.
Sylvia
Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo
Paris the Unicorn - 1991 Paris Edition
hubby has
Sven - 1994 Racing Green GT
Evil Eva - 1992 Paris Blue Turbo
no previous 480s - can't bear to sell any
Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo
Paris the Unicorn - 1991 Paris Edition
hubby has
Sven - 1994 Racing Green GT
Evil Eva - 1992 Paris Blue Turbo
no previous 480s - can't bear to sell any
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
Thank you very much. That's so helpful!
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
finaly, almost 2 years later
Roofrails, Roofrack and luggage rack are now installed.
All informations and parts...
Markings...
drilling and rust protection...
Roofrails, Roofrack and luggage rack are now installed.
All informations and parts...
Markings...
drilling and rust protection...
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
Ready!
front view
birdview
(on this picture the two small end caps are still missing, but they ar now on)
front view
birdview
(on this picture the two small end caps are still missing, but they ar now on)
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
-
- Started learning about 480
- Posts: 51
- Joined: Sat Nov 06, 2021 10:45 pm
Re: Roof rails, mounting instructions
my current
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red
480 GT Bj. 94, Steel Grey Metallic
my second
480 turbo `92, white
my first
480 ES `88, red