Faulty J-bolts on Yakima rack? - Kayak Fishing Adventures on Big Water’s Edge

spudz · 10-08-2015, 11:40 AM

I have owned a Yakima Outdoorsman 300 full truck rack for about 3 years now. I’ve got it rigged to Toyota Tundra and I typically carry 1 polyethylene kayak (~ 65 pounds) on it over freeway and paved roads. At most I’ll carry three kayaks on it ( ~ 65 pounds each = 195 pounds).

I have not had any problems with this system until recently. This past summer I loosened a “J” bolt so I could relocate a tower. The J-bolt snapped. I replaced the snapped j-bolt with a new one that Yakima provided. As I loosened the bolt on the opposite tower, that J-bolt snapped too. Thought that was odd to have another snap. All bolts had anti-seize applied to them upon initial installation, hex nuts were moving when removed from the bolts. I noticed the original J-bolts no longer maintained their original "J" shape. The hook part of the “J” shape of the bolt pulled away and no longer had the original “J” shape (see photos). I then attempted to remove another J-bolt from a different tower to see if that was becoming disfigured too. As I loosened that bolt, it snapped too. I now have had a total of 3 of 4 J-bolts snap. All 3 had snapped close to the base of the threading. Upon inspection all original 4 J-bolts are disfigured where the hook end of the “J” bolt has been pulled/stretched.

A side by side of a new J-bolt, the solitary unsnapped bolt and 2 of the three snapped J-bolts.

A pic of the bent J-bolt sitting on top of a new J-bolt.

I’m happy that Yakima replaced all the J-bolts. But they couldn’t explain why this was happening. Would like to know if any other Yakima users had similar problems? Is this a common trend in the j-bolts used for the Outdoorsman 300?

Dannowar · 10-08-2015, 12:03 PM

Three kayaks that high up I would imagine puts a lot of stress on the racks.

spudz · 10-08-2015, 12:59 PM

Typically I’d carry 1-2 kayaks on the rack. Seldom would I carry three. When I spoke to the Yakima reps they stated that three kayaks, even 4 kayaks, wouldn’t be a problem as long as I stayed below the 300# load capacity. However, they still weren’t able to explain why the bolts would fail.

RedSledTeam · 10-08-2015, 01:25 PM

It appears that you are over-stressing the J Bolts. What do they clamp and how much torque does it take to get it to adequately clamp up?

rossman · 10-08-2015, 01:27 PM

Have had my Outdoorsman for close to 10 years now on 2 trucks with the same J bolts. No problem with mine. The bottom of the J bolt should fit into an 6 inch long by 3/4 inch square of extruded aluminum. Wanna make sure you are using those and that they lay flat under the lip of the truck bed. If they are missing or not laying flat I can see them bending and breaking.

mrJB · 10-08-2015, 01:41 PM

Even though Yakima is based in Washington, I wouldn't be surprised if they are now outsourcing some parts (i.e.,China). Wouldn't want a failure while underway...

Don't know if they would be stronger, but you might want to cut down some trailer "U-bolts" and give it some stress and check before mounting. Beyond that, you could go to a machine shop and have them make you a set out of grade 5 or 8 steel...

YakDout · 10-08-2015, 02:02 PM

See if you can find higher grade bolts through www.fastenal.com

10-08-2015, 11:40 AM	#1
spudz Member Join Date: Apr 2006 Location: SoCal Posts: 78	Faulty J-bolts on Yakima rack? I have owned a Yakima Outdoorsman 300 full truck rack for about 3 years now. I’ve got it rigged to Toyota Tundra and I typically carry 1 polyethylene kayak (~ 65 pounds) on it over freeway and paved roads. At most I’ll carry three kayaks on it ( ~ 65 pounds each = 195 pounds). I have not had any problems with this system until recently. This past summer I loosened a “J” bolt so I could relocate a tower. The J-bolt snapped. I replaced the snapped j-bolt with a new one that Yakima provided. As I loosened the bolt on the opposite tower, that J-bolt snapped too. Thought that was odd to have another snap. All bolts had anti-seize applied to them upon initial installation, hex nuts were moving when removed from the bolts. I noticed the original J-bolts no longer maintained their original "J" shape. The hook part of the “J” shape of the bolt pulled away and no longer had the original “J” shape (see photos). I then attempted to remove another J-bolt from a different tower to see if that was becoming disfigured too. As I loosened that bolt, it snapped too. I now have had a total of 3 of 4 J-bolts snap. All 3 had snapped close to the base of the threading. Upon inspection all original 4 J-bolts are disfigured where the hook end of the “J” bolt has been pulled/stretched. A side by side of a new J-bolt, the solitary unsnapped bolt and 2 of the three snapped J-bolts. A pic of the bent J-bolt sitting on top of a new J-bolt. I’m happy that Yakima replaced all the J-bolts. But they couldn’t explain why this was happening. Would like to know if any other Yakima users had similar problems? Is this a common trend in the j-bolts used for the Outdoorsman 300?

10-08-2015, 12:03 PM	#2
Dannowar Senior Member Join Date: Aug 2012 Posts: 1,823	Three kayaks that high up I would imagine puts a lot of stress on the racks. __________________ "Beware the lollipop of mediocrity; lick it once and you’ll suck forever." — Brian Wilson

10-08-2015, 01:27 PM	#5
rossman Marginally Irrelevant Join Date: May 2007 Location: Bahia Asuncion Posts: 936	Have had my Outdoorsman for close to 10 years now on 2 trucks with the same J bolts. No problem with mine. The bottom of the J bolt should fit into an 6 inch long by 3/4 inch square of extruded aluminum. Wanna make sure you are using those and that they lay flat under the lip of the truck bed. If they are missing or not laying flat I can see them bending and breaking. __________________ "When beholding the tranquil beauty and brilliancy of the ocean’s skin, one forgets the tiger heart that pants beneath it; and would not willingly remember that this velvet paw but conceals a remorseless fang. " — Herman Melville Y'all come see me now, hear!

10-08-2015, 01:41 PM	#6
mrJB Senior Member Join Date: Feb 2007 Location: O.C. Posts: 352	Even though Yakima is based in Washington, I wouldn't be surprised if they are now outsourcing some parts (i.e.,China). Wouldn't want a failure while underway... Don't know if they would be stronger, but you might want to cut down some trailer "U-bolts" and give it some stress and check before mounting. Beyond that, you could go to a machine shop and have them make you a set out of grade 5 or 8 steel... __________________ "I Brake for Halibut"

10-08-2015, 12:59 PM	#3
spudz Member Join Date: Apr 2006 Location: SoCal Posts: 78	Typically I’d carry 1-2 kayaks on the rack. Seldom would I carry three. When I spoke to the Yakima reps they stated that three kayaks, even 4 kayaks, wouldn’t be a problem as long as I stayed below the 300# load capacity. However, they still weren’t able to explain why the bolts would fail.

10-08-2015, 01:25 PM	#4
RedSledTeam Daddeo Join Date: Jul 2010 Location: OC Posts: 660	It appears that you are over-stressing the J Bolts. What do they clamp and how much torque does it take to get it to adequately clamp up?

10-08-2015, 02:02 PM	#7
YakDout Brandon Join Date: Jul 2011 Location: San Diego Posts: 2,345	See if you can find higher grade bolts through www.fastenal.com