940 Roof Rail Fitting

[940Graeme]

Well Sunday is the day I will finally attempt to fit the roof rails to the 940.

I thought that this was an easy project, buy second hand rails, find bolts, fit.........but ohhhhhhh no!

Firstly, find correct fitting bolts pack (no longer available from Volvo), then work out the whole headlining removal sequence, (advice from here - thanks all), then, when fitting kit finally arrives work out how the hell it all goes together, (no diagrams available from Volvo), then work out gasket and sealing arrangements for the job, THEN build up the courage to plan the day to drill quite big holes in the roof.

Anyway, I'm on it later today, and hopefully by the time the roast beef and yorkies are ready Sunday evening JPY will be proudly wearing his new set of ally bars. I'll work out and post a guide to fitting once I've done it..........thought there may have to be some expletives deleated.

If there is anyone who has done this before, PLEASE send me advice, though I have researched the forum extensively.

Wish me luck!

Graeme

[CTCNetwork]

Hi,

1) Good luck..
2) Take photos...
3) Take measurements...
4) Enlighten us..

Des. . .

[Andy_Gibson]

good luck and take plenty of pics

I've got a set of rails in the garage loft but have never been brave enough to drill the roof of my car

As you say the fitting kit is now obsolete which might stuff me up but I guess the volvo fitting kit is just some spacers and rivnuts ?

[crogthomas]

I took some photographs of my car with roof bars for someone who was fitting some rails to their car. They might be useful to someone?

[crogthomas]

[Andy_Gibson]

mmmm so the volvo fitting kit is just a packet of rivnuts then

cheers

[crogthomas]

Originally Posted by Andy_Gibson

mmmm so the volvo fitting kit is just a packet of rivnuts then

I guess the kit includes the bolts and the threaded aluminum spacers as well. But if you're fitting a set of rails removed from a car, and have those bits as well, then all you need is the rivnuts, yes. And a tool to fit them I guess.

[940Graeme]

OK advice for those of you thinking of fitting rails.

DON'T.

I mean it. DON'T. It is a nightmare of the first order.

Especially DO NOT UNDER ANY CIRCUMSTANCES try to fit a set that were not originally available for your model year. (Like I have done.......). NONE of the internal gaps in the box sections under the roof lineing line up with the "wrong" rails.

If you really really must, I would suggest the only way to complete the job without total nightmares is to remove a set from a scrapper yourself making notes and measuring as you go, then transfer them to your car using your own notes. If I am honest, I've had to bodge it to such a degree that any advice on what I have done is useless.

However, the following general notes may be of some use:

Get the right fitting kit if you can - it does consist of alan key bolts, the ally screw in "spacer" and the brass bush. Alternatively, use the "original ones" if they haven't rusted too badly.

If you are removing old ones do so CAREFULLY. You need the black rubber gasket - as helpfully shown in the photo in a previous post. Mine didn't have these, I made new ones from a bike tyre repair kit.......

Get a good gasket sealant and seal under the rail mount on the roof AND inside. Use loads.

Low tack masking tape on the roof is VERY useful for getting the positioning right - place the rail and draw round the "feet". Do use the "low tack" stuff. Cheapo ordinary masking tape can remove the paint laquer.......I've discovered.

Once you have decided on the correct position drill SMALL pilot holes and use match sticks to check the alinement before you drill the main holes.

Leave yourself plenty of time. It has taken me about 8 hours over 2 days.

DO NOT do it by yourself - you will need at least one assistant.

I have to say, now they are fitted they do look great, (although I will always see the bits that aren't quite right), but would I do it again? NO. NEVER. YOU COULD NOT PAY ME ENOUGH!!! Just buy an estate with them fitted from the factory................really.

Graeme.

[Andy_Gibson]

Sounds like you've had a right nightmare

you say "DO NOT UNDER ANY CIRCUMSTANCES try to fit a set that were not originally available for your model year. (Like I have done.......). NONE of the internal gaps in the box sections under the roof lineing line up with the "wrong" rails."

I know there are black rails and a graphite grey coloured rails, are these different to each other and unique to different year 940's .

Do they have different spacing between them

eg black rails are designed for upto 1995 and the grey ones for 1995 onwards

[940Graeme]

Hi Andy - Basically there are only two types - the early short Aluminium or black/grey ones with four fixings (look the best IMO), and the later, longer, grey or black or body colour ones with three fixings. My problem was I was trying to fit the early ally ones to a later car (97 MY). I noticed that the internal roof box sections of mine had factory cuts out that I think would match with the mounting points for the later longer rails. My problem was there were no cuts out to fit the early shorter 4 "post" ones, so I basically had to cut out access holes into the box sections as well as drilling the roof etc etc.

I think fitting the "correct" rails would have been as easier job.........thou I say "easier" not easy!!

Graeme