How to Repair Roof Boxes in a Car? Step by Step (2023)

To repair roof boxes on a car, start by cleaning the box thoroughly and assessing the damage. Depending on the issue, you might need to fix cracks with adhesive or tape, replace broken parts, or tighten any loose fixtures to ensure a secure fit.

How to Repair Roof Boxes in a Car?

Owning a car is always a superior experience, isn’t it?! There’s no doubt about it! You’ll always feel an extra adventurous feeling by having a car. However, as they get older, things get change significantly. One of the changes can appear in the car’s roof boxes. Further, it can damage over time. But, you can fix it by yourself if you know some basic rules of the vehicle.

Car roof boxes are positioned on the roofs of the automotive and used for storage. Besides, they are exposed to the ingredients and residues. For this reason, their condition vandalizes with time. By following some moves, you can okay them quickly.

In this article, we’ll talk about how to repair roof boxes in the car – some easy steps. Let’s go –

Car Roof Box Repair – Some Simple Steps to fix it

What’s your take on repairing a car’s roof box? Is it too complicated a task?! Absolutely not! The equipment needed for repairing jobs is available in hardware stores. Therefore, you don’t have to take the extra burden on it. Now, let’s check out the procedures for fixing the roof box in the car –

Step 1 – Sand the Place

Find out the crack inside of the car’s roof box. Then, start sanding the whole place around it. But, which element should you use? Our recommendation is coarse-grit sandpaper. The fiberglass will adhere closely to this thing.

Step 2 – Cleanse the Place Properly

It is necessary to cleanse the whole place properly with clean water or alcohol. Otherwise, you can’t expect a strong bond with the roof box.

Step 3 – Heat the Thing!

It’s time to heat up! Allow the propane torch to get over the surface. When the flame can touch the surface, it will erode the area and remarkably enhance the overall adhesion. Therefore, the adhesive’s adhesion improves outstandingly and gets a special coating.

Step 4 – Mix the Epoxy

Now, it’s the mixing time of the epoxy. However, make sure that the percentage is exactly the package suggested. A small batch of epoxy is enough. Then, you have to mix it accordingly. Keep the mixed ingredient on a disposable paper plate.

Step 5 – Apply the Epoxy

Apply a small amount of epoxy to the sanded area of the roof box. After that, place some lightweight fiberglass fabric over the rift. Henceforth, it will be best if you can remove the air bubble from the fiberglass. This is how it can work properly.

Step 6 – Repeating the Procedure

Take another batch of fiberglass and repeat the whole procedure with epoxy one more time. After putting the fiberglass fabric in the wet adhesive, spread the entire thing with a spreader thoroughly. Nevertheless, don’t rush while doing it. Otherwise, things could go wrong.

On the other hand, if there are more layers, keep redoing the process.

Besides, take time to cure for around 10-12 hours. To finish it in a sophisticated way, you can consider painting.

Warning Message – While mixing the epoxy, better wear gloves in your hands. Epoxy can be dangerous to the skin and taking precautions is necessary.

Waterproof Cargo

How to Resist the Roof Box Leak in the Car?

There are various reasons that roof boxes can get leaked. To prevent it, you can take some practical measurements. Let’s check out –

  • Rust is the common enemy of a vehicle. The rust and corrosion can cause massive damage to the roof box in the car. Therefore, you should clean it regularly.
  • The roof area needs to be painted periodically. Yes, cleaning is essential. But, keep remember that just cleaning isn’t enough for your roadster’s roof box. As a result, polishing is a must. This is how a car’s roof box can get protection from rain, snow, extreme heat, and other natural threats.
  • Be careful when installing a roof box. Sometimes, the box fails to fit inside of the car correctly. For this reason, substantial damage can happen to the box. So, beware of this and establish the box accurately inside a vehicle.

Some Important Roof Box Safety Tips

A road trip is always enjoyable. But, being stuck in a car for hours with little room for movement can bring an unpleasant situation. That’s why loading up a roof box with belongings can help immensely. Nevertheless, adding a load to the top of the car could be risky.

Therefore, here’s something you have to know before making your entry into the road –


During making a plan on rooftop packing, it’s better to know the weight limit of the rooftop and vehicle. Do you have to pack a lot of belongings? Hmm. So, knowing the weight could ensure that you’re on a correct path. Remember that being overweight could lead to a severe accident.


A well-packed roof box generally increases the center of gravity of the car. For this reason, the vehicle can wobble at high speeds. As a result, there’s a big chance the load can fall into it and cause unimaginable problems while driving. So, a balance is needed.

Ensure that the box is well-balanced while it carries your properties.

Installing in the Box

Sometimes, cars come with a roof box. But, if the vehicle doesn’t come with it, you have to purchase and install the product. Moreover, you have to ensure that the box perfectly fits the car. Generally, the roof box comes with a connecting point. Besides, you can join this point with the car.

But, if the point can’t be attached to the car’s roof, it will cause a massive problematic situation. To skip such an unwanted condition, you can take advice from an auto professional.

How to Repair Roof Boxes in the Car? – FAQs

Can the roof box damage my car?

If you can set the box accurately as per the suggestion of the manufacturing company, you won’t face a problem and there’s no chance that the box could damage your car.

What is the best place for a roof box in a car?

Try to distribute the weight equally as possible you can. If you feel that the load is much heavier, you can keep some more oversized items in the backseat of your vehicle. On top of that, you have to ensure adequate airflow around the box. Therefore, the box should stay closer to the back of the car rather than in front.

Final Thoughts

So, this is our discussion on how to repair the roof boxes in the car – some easy steps. Although these formulas are pretty effective for repairing roof boxes, you can consult with a professional if enormous damage occurs. However, we think prevention is the best measurement when it comes to leaking.

Thank you for reading! Until next time, goodbye!

-our editorial board has reviewed this article and has been approved for publication according to our editorial policy.

Best Seller List of Roof Cargo Boxes:

Bestseller No. 1
JEGS Rooftop Cargo Carrier for Car Storage - Large Roof Rack Cargo Carrier - Heavy Duty Weatherproof...
  • Secure & protect your gear in this 18 cubic ft. HDPE plastic hard shell vehicle cargo carrier; high-capacity interior dimensions 57 L x 38 1/2 W x 17 3/4 H inches; aerodynamic design for fuel efficiency
  • Weatherproof storage for your luggage with a four corner locking system, front latch, and weather-tight seal for ultimate car rooftop protection and security
  • Easy & convenient loading and unloading from either side of the car make for smooth travel and hassle-free storage
  • No tools required, easy assembly and installation. All mounting hardware and simple instructions are included to get you safely on the road quickly
  • Made in USA, limited lifetime guarantee. The JEGS car top carrier’s high-quality construction and performance give you peace of mind
  • Holds 3 golf bags
Bestseller No. 2
SportRack Vista XL Rear Opening Cargo Box,Black
  • 18 cubic foot (510 L) internal cargo capacity
  • Made from durable UV-resistant ABS material
  • Rear opening for easy access away from traffic
  • Tool-free mounting hardware for easy installation and removal
  • Includes key and lock to secure contents in the box, and the box to your rack
  • Fits SportRack Rack Systems, square bars, round bars and most factory racks (check fit guide)
  • Dimensions (LxWxH): 63 x 38 x 19 in / 160 x 96.5 x 48 cm
  • Min-Max Crossbars Spacing: 23 5/8 - 29 3/4 in (60 - 75.5 cm)
  • Max Weight Capacity: 100 pounds (45 kg)
Bestseller No. 3
Auto Dynasty Heavy Duty Hard Shell Roof Top Mount Car Storage Travel Luggage Box Cargo Carrier with...
  • ▶️ This roof top storage box is universal fit for mounting to max 13 inches wide cross bar, please check the dimension before purchase.
  • ▶️ The package comes with [1] 53 inches length storage box, [2] security lock key, and [4] heavy duty tool free installation mounting brackets.
  • ▶️ It is constructed of rugged, impact-resistant ABS material to ensure a long lasting life in outdoor conditions. More, it can open from the side and stay open till you close it with the strong support arm.
  • ▶️ Opens on the passenger side to 14 inches wide to store bulky items from the side and stays open till you close it, and it is very easy to install without any tool required to assembly.
  • ▶️ Overall Dimensions: 53" L x 34" W x 15" H | Capacity: 11 Cubic Feet and up to 110 LBS
Bestseller No. 4
Thule 614 Pulse Rack, Medium, Black
  • Functional rooftop cargo box provides 14 cubic feet of additional packing space
  • Rugged and durable design keep contents protected
  • FastGrip quick-mount system assembles in minutes
  • Passenger-side opening for easy loading and unloading
  • Central Locking system provides maximum safety
  • Thule Comfort Key can only be removed when all locking points are securely closed
  • Fits 3-5 snowboards (max length: 155 cm)
  • External dimensions: 67 x 35 x 16 inches; Internal dimensions: 61 x 33 x 14 inches
  • Load capacity: 110 lbs; Product weight: 34 lbs
  • Height off crossbar: 16 inches. Fast and secure mounting
Bestseller No. 5
287 Reviews
TACTIK Rooftop Cargo Carrier Hard Shell, X-Large, Dark Slate - Rooftop Cargo Carrier for Top of...
  • UNLOAD FROM BOTH SIDES - the patent-pending dual side-opening design allows you conveniently load and unload your travel luggage and gear from both sides of the rooftop cargo carrier so you're out of the way of traffic while you unload
  • FUEL EFFICIENT DESIGN - the aerodynamic design of the roof rack cargo carrier reduces drag and wind resistance to minimize fuel economy disruption. The 18 cu ft carrier measures 57" x 38.5" x 17.75" and the 10 cu ft carrier is 46.5" x 30.5" x 17.75"
  • SECURE LOCKING SYSTEM - this car top carrier secures your luggage with a four-corner cam locking system to ensure that the lid won't blow open while you're on the road with a keyed theft-resistant lock for peace of mind at stops. Includes 2 keys
  • WATERPROOF & UV RESISTANT - proudly made in the USA, this waterproof rooftop cargo box is manufactured from durable, all weather high-density polyethylene material that includes a built-in UV stabilizer that resists cracking and fading
  • MOUNTS TO CROSS BARS - the car rooftop cargo carrier is a quick and easy no-tool installation and allows you to mount to your vehicle's cross-bars (not included). Pre-drilled mounting holes for cross-bar attachment are drilled 24" on center
Bestseller No. 6
TUFFIOM 11.65 cu.ft. Rooftop Cargo Box w/Keys, Hard Shell Dual-Side Opening Waterproof Roof Mount...
  • DUAL-SIDE OPENING FOR EASY ACCESS: Dual-side opening design allows you to open it from either the driver side or the passenger side, which brings more convenience for loading and unloading. (NOTE: There is protective film on the lid. Please peel off the film before use.)
  • FAIR CAPACITY: With 11.65 cubic feet maximum storage capacity and 150lbs loading capacity, the roof cargo carrier can allow for more space in your car. What’s more, its streamlined design will reduce drag and noise during driving.
  • LOCKING SYSTEM FOR SAFETY: It is designed with locks on both sides and comes with keys for protecting your valuables. And the stiffeners at the bottom of the roof cargo box strengthen its stability.
  • EASY TO INSTALL: It is simple in structure and light in weight (approximately 31.3lbs). It won’t be difficult for you to lift it and install it to your car. And it can work with most vehicles with crossbars, such as car, suv, van, etc. Applicable Cross Bar: Max. Width 2.36”. Max. distance between bottom holes for installation: 25.59”. Min. distance between bottom holes for installation: 18.5”.
  • QUALITY MATERIAL FOR DURABILITY & BETTER PROTECTION: Made from ABS material for long-lasting use. And it can protect your luggage or equipment from being exposed to sun, rain or dust. And it is protected with 3-Year Warranty.
Bestseller No. 7
DNA MOTORING Rooftop Cargo Box Carrier Lockable Heavy Duty Car Top Storage Case, Capacity 110 Lbs,...
  • 【UNIVERSAL】This extra long rooftop cargo carrier fits for vehicles with cross bars only, no tool assembly & installation. Increases vehicle cargo space without impeding on passenger comfort.
  • 【LARGE CAPACITY】Rooftop cargo box provides 11 cubic feet of additional storage space. The maximum storage capacity of 110lbs when evenly distributed. And it can be opened up to 14" wide to store bulky items.
  • 【ROBUST DESIGN】Constructed of rugged, impact-resistant ABS material for long-lasting durability, able to protect your contents from exposure to the inclement weather.
  • 【SECURITY LOCKING SYSTEM】Includes key and lock to secure valuables in the box, to ensure cargo safety and s proper lid alignment. It can open from the side and stays open til you close it.
  • 【SPECIFICATION】Size: 11 Cubic Feet Internal Storage, 110lbs Max Capacity | Overall Dimensions: 53" L x 34" W x 15" H | Surface Finish: Black Texture Finish
Bestseller No. 8
Thule Force XT Rooftop Cargo Box, X-Large
  • A versatile roof-mounted cargo box for everyday use
  • Provides 18 cubic feet of additional packing space
  • Designed to fit a wide range a vehciles with maximum space efficiency
  • Quick-mount system "clicks" when roof box is secure and properly mounted
  • Dual-side opening for easy access to all areas of the box, from either side of the vehicle
  • Full trunk access with no roof box contact
  • Fits 5-7 pairs of skis / 3-5 snowboards (up to 195 cm)
  • External dimensions: 82.75 x 33.75 x 17.25 inches
  • Internal Dimensions: 77.5 x 29.5 x 15.25 inches
  • Load capacity: 165 lbs; Product Weight: 47 lbs
Bestseller No. 9
15.5 Cubic Feet Rooftop Cargo Carrier Box, Heavy Duty Hard Shell Roof with Security Keys, Waterproof...
  • Perfect for Road Trip: Take the cargo box to the park, the beach, the sports field, or any place you need to store. Works on all vehicles with rack, suitable for cars, vans, SUVs, etc. Sleek aerodynamic design to reduce drag and has less noise.
  • High Quality Material: The roof box is manufactured from sturdy ABS and PMMA material for long-lasting use, able to protect your valuables from exposure to the elements and can load 130 lbs capacity, suitable for round, square, factory and most aerodynamic bars.
  • 15.5 Cubic Feet Cargo Box with Car Trunk Organizer: With the large capacity, the roof cargo box can help you securely carry 15.5 cubic feet worth of essentials, and can increase vehicle cargo space without impeding on passenger comfort, more capacity, and more pleasure!
  • Secure & Convenient Use: In order to keep your belongings secure, this vehicle cargo carrier is designed with the security lock that has keys. More importantly, Dual-sided opening for easy access on either side of your vehicle to increase efficiency and convenience.
  • Easy to Install: With equipped hardware and detailed instruction, the car rooftop cargo carrier is easy to be mounted to the car top. Then you can start a hassle-free trip with your family and friends to appreciate the wonderful scenery along the way.
Bestseller No. 10
DuraLiner Rooftop Cargo Carrier for Cars - Waterproof Hard Shell Roof Top Mount Car Storage - Easy...
  • LARGE STORAGE CAPACITY: The Car Rooftop Cargo box offers more than 10 cubic feet of storage capacity, making it a perfect choice for carrying bulky items like luggage, camping gear, & sports equipment. Car topper luggage carrier helps to free up valuable space inside your vehicle for passengers & other essentials. Whether you're going on a leisure trip or a work-related one, DuraLiner rooftop cargo box has enough room to hold all your necessary items.
  • ROBUST & COMPACT DESIGN: The Cargo rooftop box is crafted to fit most roof racks with ease and is simple to install and remove. The hardshell rooftop cargo carrier is made from durable materials, enabling it to withstand harsh weather conditions & rugged terrains. Duraliner roof carrier is watertight & lockable, ensuring your belongings stay protected from water damage.
  • STURDY MATERIAL: Heavy-duty plastic resists UV damage and maintains a rich finish to protect your belongings from weather. The Cargo Box has a sturdy and long-lasting construction made possible by High-density polyethylene (HDPE), which can withstand harsh environmental conditions.
  • EASY INSTALLATION: DuraLiner Cargo Boxes are simple and easy to install. The tool-free assembly and U-bolt securing feature make it a quick process, allowing you to hit the road in minutes. These cargo boxes can be mounted with ease onto most vehicles with Roof rack cargo boxes. Vehicle Cargo Carriers design features a sealed lip, rear entry, and a four-corner latching system to ensure the safety and dryness of your belongings. It is durable & recyclable.
  • COMPATIBLE WITH MOST VEHICLES: Car roof cargo carrier is compatible with numerous car makes and models, including Chevrolet, Ford, Isuzu, Jeep, Mazda, Mercedes, Mitsubishi, Nissan, Sprinter, Toyota, and more. Its universal mounting system is adaptable to various roof rack systems, making it a convenient option for customers with different car brands. The Rooftop cargo is specifically designed to fit and function with the roof racks or crossbars of these particular car models.

Last Update : 2024-03-26

Automotive products are like an addiction to me. Years ago, I started my job at a Roof Box installation co. Then I realized that I have a passion for cars. It is a perfect scope to share my different experiences about automotive products.

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