Installing Tracks and Reinforced Shells

So I've researched a lot on opinions on where one should install their tracks to mount rails. I have a Snugtop Rebel with the Sportsman Package to handle 500lbs loads and like an idiot I didn't order it with tracks from the beginning.

The dealer and everyone else charges an more than $300 just to install and at that price I'd rather do it myself.

What I have issue with is where exactly to drill and lay the track on? Should it be just outside the honeycomb reinforced structure to avoid crushing when I tighten the bolts or just outside the honeycomb?

Please advise, if you have pics that would be great.

Thanks!

 

Yes, definitely outside of the honeycomb part. That stuff is typically cardboard (or was anyways) and will crush if you try to tighten your mounting bolts. I was told by the dealer that the reinforced part is to keep the top of the shell rigid so that it keeps its shape and doesn't vibrate and crack the paint and gelcoat. I looked at another ARE shell that was on the lot that had the tracks already mounted and got an idea where they mounted them at the factory and went from there.

Use the kit Yakima, and probably Thule, make for this purpose and it should come with some plastic and metal nuts that are rounded so you don't gouge your head if and when you bump them. Yakima calls them "track nuts"; their website sucks but you can see them in this install picture: https://explore.yakima.com/custom-install#fiberglasstrack They advise using a small amount of silicon, not globbing it all over the place. My brother was trained by Yakima how to install the tracks when he worked at a bike shop and advised the same thing so that's what I did. So far no leaks that I'm aware of and they've been on since 2006 and I definitely haven't been gentle on them.

I don't have any decent pictures showing where mine is mounted.

Incidentally, I mounted some D rings under the nuts when I was installing mine so that I could use a gear hammock, overhead bungee net or run some paracord front to back to drape blankets over to create a warmer sleeping area. They look like these:https://www.lowes.com/pd/Hillman-4-Pack-D-Ring-Large-Picture-Hangers/3029190 You'll need to open up the rearmost hole slightly to allow the Yakima nut to fit. Easy to do with a step bit. I'd recommend painting them first though as mine have surface rust on them, I guess from condensation and just temp changes.

 

The deciding factor for me when I bought my shell (Ranch Sierra) is the reinforcement in the roof is 3/4” plywood, not cardboard.