MetroMPG (or anyone else with a good suggestion on this),
Any tips on how to attach the side panels to the C-pillar and the quarter panel? This is turning out to be important; the clever mount brackets I built won't pull the forward and rear corners of the side panels against the body.
I suggested rubber expansion plugs (aka well nuts) to a friend of mine.
Flange side (right) is where screw goes in.
The plug is inserted in opposite direction here; the flange is on left side under the washer.
My friend is concerned about
:
A) There's additional folded-over steel layers at the top where the roof & C-pillar meet, put there for strength. Probably don't want to drill into there where it's supposed to have strength? But that's exactly where one of my attachment points needs to be. I haven't come up with a fix for that issue.
B) The expansion plugs will allow rust sooner or later. We've both seen it happen, but 10+ years after a roof rack was installed. I think I can delay rusting long enough by priming the drilled holes and maybe also some silicone glue smeared on the expansion plug before inserting it.
I still like expansion plugs but I'm open to other suggestions.