Question about Thule 668 Frontier ES Roof Box - LL Bean

Open Question

How to repair a cracked roof box lid

Hi there, I've managed to crack the lid of my roof box (badly), there's some loose bits as well. What's the best way to repair?

Posted by on

  • jkmacdonald Jan 24, 2009

    did the same thing - backed out of my garage when the door wasn't quite open and SMASH! I'm going to try Goop Contact Adhesive to put the bits back together then seal 'er up with some fiberglass patches (the kind you'd fix a canoe with). I'll let you know how it turns out.


1 Suggested Answer

  • 2 Answers

SOURCE: cracked thule box is what Thule recommends you use to seal your crack :) -- it is an ABS patch kit and is waterproof as it is used for permanent canoe and kayak repairs. it is NASA designed.

I am using it on my Atlantis 1800.

Posted on Aug 25, 2009

Add Your Answer

Uploading: 0%


Complete. Click "Add" to insert your video. Add



Related Questions:


How to fit a roof box

A roof box is one of the best ways to increase the capacity of your car - but are the easy to fit? We spoke to an expert at Thules who gave us a tutorial on how to do it...

on Mar 26, 2014 | Thule 668 Frontier ES Roof Box - LL Bean

2 Answers

Strut on Thule Atlantis 1600XT popped off. How do I re-attach it?

Put your carrier on a pair of saw horses and clamp down firmly then open the lid as it now stable and clamp your strut with a wide jaw wood clamp. Apply just enough pressut to start the ball into the socket and finish with your hands. Steve Parks

Jun 23, 2012 | Thule 686 Atlantis 1600 Cartop Carriers

2 Answers

The lock on our Thule roofbox has jammed with key in it, it has locked, but key not turned enough to remove it. We cannot open it, or lock it enough to remove the key. Any tips to try to free it up?

I know this is old but there doesn't seem to be much on the web about this common problem. If your roof box lock appears to be jammed, key stuck in, broken off etc here is my advice based on what happened to mine. Basically the issue is not the lock but the sliding locking bar inside the box, when you lock or unlock the lock you are just turning a small Lever inside the locking bar mechanism which slides the locking bar left or right to clamp or release the 3 hinge pins on the lid. The locking bar slider is aluminium, about 4 feet long and a lot for the little key to move, especially when dirty, clogged with sand etc. I'm my case both sides were seized solid - it was assumed that the locks themselves were seized solid these were forced until the keys snapped off. One bit I picked out with a paper clip, the side I had to drill the whole barrel out. Fortunately my lid was open so I was able to free the sliders inside - wd40, gently tapping the end of the slider back and forth until it was free. New lock barrel, sorted!

May 02, 2012 | Thule 668 Frontier ES Roof Box - LL Bean

1 Answer

Line crack of roof.

I have a solution for cracking of these Thules.
The stores that sell these, carry a patching kit. It's a 3x8" piece of the same material with adhesive on one side. You can take a heat gun and soften the patch and place it over the crack and shape to fit before it cools. I've had 2 Thules on the roof of my excursion with stress cracks at the anchor points. This stuff really does the job and it's really inexpensive.
I have them on both boxes at all stress points... It has solved this issue.

Aug 14, 2010 | Thule 668 Frontier ES Roof Box - LL Bean

1 Answer

Fxing cracked carriers


As you know when a solid piece of material is damages, the structural integrity of the item is damaged, and it doesn't help that ABS is a very unfogiving material. I see Cartop Carriers all over my city with scuffs on them because the things are simply easy to forget that they are even up there!

In my research on your issue I found a material that should fix your cracked carrier and ensure that you will have many more years of enjoyment with it.

To answer your question, Fiberglass is not the proper material to use on ABS. Fiberglass is essentially a "Band-Aid" on ABS because the bond will only last a couple of years.

For this job you will need to use a compound called "Re-Plast" manufactured by the automotive parts company Wurth.

The benefit of Re-Plast is that it hardens into a plastic that bonds well with ABS, and it bonds FAST! So work quickly.

The Re-Plast will give your carrier a "scar" but should patch up your crack and increase your structural integrity. The good thing about Re=-Plast is that if you want to, you can paint over it to match your carrier's coat, to conceal the "scar" even better!

You can order Re-Plast directly from Wurth on their website link that is found below.

If this does not solve your issue, or if you have any more questions, please leave a comment on this thread and I will be more than happy to assist you further!

Happy New Year!

Feedback is appreciated!

Jan 01, 2010 | Thule 686 Atlantis 1600 Cartop Carriers

2 Answers

The catch/lock on the thule roof box broke - need a repair / replacement


Any Thule dealer should be able to sort this one out for you.

Have a look through Thule's website to find the model and possibly you could get it online if it's sold as a user changeable accessory..

Sep 02, 2009 | Thule 686 Atlantis 1600 Cartop Carriers

4 Answers

Cracked thule box is what Thule recommends you use to seal your crack :) -- it is an ABS patch kit and is waterproof as it is used for permanent canoe and kayak repairs. it is NASA designed.

I am using it on my Atlantis 1800.

Mar 30, 2009 | Thule Winter Sports

1 Answer

Cracked cargo box (yakima)

good old duct tape... i would get some silicone caulking and run beads along the cracks in the box to seal the water out. not sure what colour that is but the caulking comes in many colours as well as clear.


please take a moment to rate this solution.. thanks

Feb 05, 2009 | Yakima Fat Cat 4 Ski and Snowboard Rack

Not finding what you are looking for?
Thule 668 Frontier ES Roof Box - LL Bean Logo

Related Topics:

2,837 people viewed this question

Ask a Question

Usually answered in minutes!

Top Thule Winter Sports Experts

ray gallant

Level 3 Expert

37616 Answers


Level 2 Expert

150 Answers

Are you a Thule Winter Sport Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides