Thule 9403 fitting issue?

[Gixermark]

Hi dom_e, thanks for the reply, only problem is you haven't actually explained exactly what you have done / had done! I haven't a clue so could you try to explain what modification you did please?
Many thanks

[Simon Jones]

The rack was angled up at the back, so I filed and rubbed down areas of the two main tubes that support the bikes back to bare metal, then cut through the undersides, not quite all of the way through. I then cut out a notch representing the desired angle to modify the tilt, bent the rack to the corrected angle (horizontal to the floor) and took it to a friend at a garage to re-weld.

The way I've read it is that he's cut a V shaped sliver out of the tube and then had it welded back together. Imagine your arm as being the tube, but instead of having it straight, the elbow is bent slightly. Sounds pretty straightforward...

[dom_e]

Spot on Simon. I'll try to take a pic ASAP.

I cut out a thin wedge/sliver out of the two main support tubes that extend from the clamp mechanism backwards at about 15cm from the clamp mechanism. I did not cut all of the way through, just enough to allow the tubes to bend and correct for the lifting. Note - before cutting, I filed and sanded back and area either side of where the cuts would be to bare metal (to enable a clean weld). I then asked a friend at a garage to weld the tubes back together before re-painting.

[weebrian]

I've got the 9503, well used with no problem. Stays horizontal when the bolt is tightened. Only gripe is that even when it is tilted, the rear door won't clear it to open.

[dom_e]

I removed the hook and hand tightening nuts and made it a non tilt rack. The Boot now clears it.

[Gixermark]

Just as an up date :

Had a look at all the above info ( decided against cutting the Thule bits etc! ) & came up with a much easier but effective option.

Removed the tow ball, had a friend weld a small steel bar ( approx 5mm deep x 8 mm height x width of tow ball ) to the very top of the tow ball where it meets the tow bar. Re attached to the tow bar and the effect is a slight 'tilt' to the ball ....can't see it to the naked eye but the outcome is the Thule bike rack now sits perfectly flat allowing for 3 bikes to be loaded easily ( bike nearest the rear door has to have the handlebars turned! ) ... We don't tow anything only had the bar fitted for bikes but even if we did, the ball will still work ok.

Now if we decide to sell the bike rack we still can as it is original, if we sell the Bongo we can advise the new owners re the above or just fit a new tow ball.

Simple but effective are often the best results!!!!

We will be at the Bash if anyone wants a nose!

[dom_e]

An interesting solution. What stopped me doing something similar was that it would result in the bolts not going in straight and tightening flat to the tow bar plate. Did your solution overcome this?

[Gixermark]

An interesting solution. What stopped me doing something similar was that it would result in the bolts not going in straight and tightening flat to the tow bar plate. Did your solution overcome this?

No, it didn't 'overcome' this but I am happy with my solution!

Why I here you ask?

My first try was just to undo the 2 bolts, drop the small steel bar on top of the bolts and re tighten. This gave the desired effect but when I 'waggled' the Thule bike rack it was clear the bar would bounce out leaving the bolts loose and the Thule rack dangerously wiggly. By having my mate weld this steel bar to the tow ball itself, it will now NOT bounce out and whilst there is a small gap between the ball & tow bar it still meets 'top & bottom' and the bolts are fully tightened to the correct torque also the tow ball is still fully usable ( ie I could tow if required / the Thule bike system now sits flat and level ) giving me a cheap and easy option without cutting the Thule bike rack or any other ideas mentioned.

[Gixermark]

As they say, pictures say a thousand words!
The 1st 3 photo's show just how bad the angle was, clearly showing it would be impossible to carry the bike closest to the rear door! TT make excellent tow bars so it isn't down to design ect!







The next 3 photo's show the improvement re the angle and how it sit's slightly up but when combined with the weight of the bikes, it sat perfectly flat as you would expect. The fourth photo showing the towball is work in progress ... clearly shows the added steel bar at the top ... just in the process of second coating with smooth hammerite!

[dom_e]

Certainly neat. I'd still be a bit wary of bolts not tightening flat to the plate, but if you keep an eye on it and it's fine, good job

[MTBApple]

This might be the issue I'm having with my newly purchased 9503. I need about 1cm more to clear the end of tubes closest to tailgate (I've even removed the third (closest) rack.

Pierre