Alu-Cab Contour Canopy Mounting Bolts Do Not Fit In Rail

Hi, I am posting on behalf of my brother, who bought and waited 4 months for an Alu-Cab Contour Canopy. The issue is the mounting bolts do not fit inside the rail to shift the bracket over to the middle. He reached out to support who said it is because there is paint build up inside the rail, but scraping it seems more likely that it is straight aluminum rather than paint.

There also seems to be zero help online about the canopy either. So, would anyone recommend it try to be sanded down(it is very difficult to scrape inside the rail)? Or try to find a different size hex bolt head to slot inside? Or anything else because it is seeming like it is a faulty canopy.

Getting a quality picture is difficult too, but I hope it shows that the inside of the rail is too shallow for the head of the bolt.

 

Can you grind down part of the bolt head and make it fit? Put it in a vice....grind until it slides in.

 

We were taking a file to it, but it is also looking like the threaded part of the bolt is too big to even slide through as well.

 

Unfortunate that you have to fix something that should work, but True Value probably has stainless and zinc plated ones that will fit.

Also, are you putting a washer on the bolt? Looks like there’s a ridge or washer on it making the head thicker.

 

Maybe try a button head bolt with a square base like this?

 

There is no washer on it, we are currently just brute forcing with a crowbar to put next to it and a hammer to hit it along the rail. It’s working and probably better than trying to sand the whole thing.

 

It came with ones that look similar to it, I mean I think even just trying to use a smaller bolt head like a 7mm would maybe be easier for this, but the threaded part is still too big for the rail too.

 

Well, good thing is you won’t have to take those out!

 

Looks like it’s the wrong bolt size/type for the rail. I’m not familiar with Alucab but that style of rail usually takes carriage bolts like the ones pictured above. They are sold at any Home Depot or Lowe’s and it’s usually the 1/4 inch size. Prinsu uses that style along with others. The square part slides easily into the slot of the rail. Maybe post a picture of the bolt you’re using. Seems like the ridge is too thick not allowing it in the rail.

You can also try another hex bolt that doesn’t have that ridge under the head. Similar to the ones front runner uses like a simple 3/8 hex bolt.

 

All AluCab products like these require M8 bolts in the camper tracks, both inside and out. The roof tracks are M10 bolts. They do not use carriage bolts, but simple M8 hex bolts.

Some folks have said that the powder coating process leaves a bit too much residue inside of the tracks. It takes some effort (with the prybar/hammer like you mentioned) to get the bolts in.

My Canopy Camper did not have this issue.

 

Also, in your first photo, the bolt will only go in with the top and bottom of the bolt being parallel to the track. You have it in the photo at an angle.

 

wow, that's terrible customer service and quality control! Probably something they'd want their authorized dealers installing.

 

It's the powder coating that is causing the issue. The easiest way to deal with getting them into place is to get them started in the track, put a nylock on the bolt and then use a socket to wiggle and push it into place. It will slide into place with a little back and forth.

 

OK4wd (the place that distributes all AluCab products in the US) has the best customer service that I have ever encountered. They are a truly standup company.

The quality control (AluCab itself) does seem to be hit or miss. This issue is not typical of all Contour Canopies or their other products.

 

That’s what I wondered. Sometimes it pays on certain things to use their local distributors.

 

I have had nothing but excellent service from both Alu-Cab and OK4WD. Powder coating isn't an exact science and if too much powder ends up in the extrusions, it will make getting the fasteners inserted more of a chore but it's easy to overcome.

 

Agreed.