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How to Repair a Cracked Thule Box

Thule boxes are mounted to the roofs of vehicles and used for storage. The units sometimes take a beating because they are exposed to the elements, stray rocks and debris. If your Thule box has seen better days, it can be repaired with items easily found at most hardware or home-improvement stores. Repairing a cracked Thule box is a project most people can achieve in one afternoon or less.

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  1. Sand the area around the crack inside the Thule box. Use only coarse-grit sandpaper, instead of fine-grit, so fibreglass will adhere better.

  2. Cut at least two sections of fibreglass cloth. Each section should be at least two inches beyond the edge of the crack in all directions.

  3. Mix the epoxy using the ratios specified on the package. Put mixed epoxy on a disposable paper plate.

  4. Apply a layer of epoxy to the sanded area on the Thule box.

  5. Place the fibreglass fabric over the crack. Remove air bubbles from the applied fibreglass with a squeegee.

  6. Repeat this process with epoxy and your second layer of fibreglass. If you choose to use more than two layers, continue to repeat this process until all layers are used.

  7. Apply another thin layer on top of your final piece of fibreglass. Squeegee any air bubbles out to seal the fibreglass matting.

  8. Warning

    Always wear rubber gloves when handling epoxy. Epoxy hardens quickly and can irritate your skin.

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Things You'll Need

  • Fibreglass cloth
  • Epoxy resin
  • Rubber gloves
  • Squeegee
  • Scissors
  • Coarse-grit sandpaper

About the Author

Kennedi Rose is an Atlanta-based journalist who began her career in 2005 as a newspaper reporter covering the education beat. She has written for a wide variety of commercial, trade and online magazines covering food, drink and the retail sector. She holds a Bachelor of Arts in sociology.

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