Trailrax half-rack used for hoisting 2-door hardtop roof (w/ remote electric hoist)

Mtea · Sep 6, 2024

I installed a wireless remote electric hoist in a steel channel for taking off my 2dr roof (parts cost about $270). The Trailrax half-rack seemed to be attached pretty well and I didn’t really want to take it off so I built a frame out of 1” square steel tubing (1/8” wall thickness) to facilitate attachment to the roof rack (1x4’ piece, 2x2’ pieces, a few 3/8” eye bolts). I was also afraid of damaging the seals on the roof using straps to go underneath as I’ve seen some do. A little trial and error finding the right balancing point and I can lift the roof off and slide it away.

I don’t know what Trailrax thinks of this, but it seems strong enough and certainly is less hassle than taking off the half-rack. Use your own judgement, but I’m happy with it for now. Question: Will the roof keep its shape hanging this way?

I have to say that my 2.3 BB 2dr non-sas auto feels like it has even more zip with that load off the back.

RagnarKon · Sep 6, 2024

Huh, interesting.

That is a level of sketchiness I don't know if I personally would be comfortable with. Maybe to help lift the hard top off the Bronco, sure, but I don't know if I would leave it like that personally.

Though I also admit I'm far from an expert, and the extensive research I did before making this post involved looking at my oversized gut and asking it what it felt like. Curious what others think.

Mtea · Sep 6, 2024

@RagnarKon the hoist is rated for 440 lbs, the roof weighs 80 lbs and the rack adds probably another 20 lbs so shouldn’t be an issue there. What I don’t know is how strong the attachment of the half-rack to the roof is. The steel on the rack looks like 1/8” so should be pretty strong. I feel you though, so I won’t be sitting under it to eat lunch.

RagnarKon · Sep 6, 2024

Mtea said:
@RagnarKon the hoist is rated for 440 lbs, the roof weighs 80 lbs and the rack adds probably another 20 lbs so shouldn’t be an issue there. What I don’t know is how strong the attachment of the half-rack to the roof is. The steel on the rack looks like 1/8” so should be pretty strong. I feel you though, so I won’t be sitting under it to eat lunch.

Yeah I'm not concerned with the hoist at all.

Mostly concerned about the hardtop. The hard top shell itself is four separate pieces bonded together with what I assume is some sort of glue/resin. One of those separate pieces is the roof of the hard top, which is what the hoist is lifting with the help of the Trailrax rack. But the remainder of the top (sides and back) is held up with just that glue/resin, and that's the heavy part with the glass.

I'm guessing it'll be okay?? Maybe?? Not sure. I really have no idea.

Fly · Sep 6, 2024

Kind of the same concept as a Lange hoist design

Tilzbow · Sep 6, 2024

I’ve been thinking about doing this with my full rack. I’d attach the front portion of the rack to the steel hard top mounting points somehow so itd have four attachment points like yours.

Since I won’t remove the hard top again for months, please report back if your hard top falls to the ground :wink:

Kidding aside, it seems like it should work fine since the hard top is rated to carry more weight than it weighs if I remember correctly.

Bschurr · Sep 7, 2024

Very clever & great ingenuity @Mtea

I am not a structural engineer but, I play one on the internet - it would seem to me that the hardtop is designed to have the load (weight/structure) of the top vertically oriented to attach to the bed rail of the Bronco. Storing it from the top is essentially causing the weight of the top to be distributed horizontally which might not be appropriate to the top’s structural integrity. Just my $0.02.

(BTW - likely not an issue lifting the top off via horizontal stress but long term storage may be problematic. YMMV)

Tl:dr - Good stuff & keep us posted on long-term storage success.

Mtea · Sep 7, 2024

Thanks all for the thoughts. Because the hoist makes it pretty quick and easy to take the roof on and off I’m thinking there won’t be any long-term (say six-months) storage. Probably more like a week or two, but who knows. I’m in the mountains in Idaho so the roof will definitely be back on in a month because it will be freezing out. I’ll post if I encounter any storage/structural problems.

Offroad Newb · Sep 9, 2024

I have a similar set up and lower the top down to the ground when the Bronco is out of the garage.

Off topic, but how do you like the half rack? I’m considering one for my 4 door. How is the wind noise?

Mtea · Sep 9, 2024

@Offroad Newb I’m leaving my rack hanging for now mostly because it’s easier to move on the strut if I need to get into the closet. The 2 dr half-rack does add some wind noise but I’m not at speed all that much so doesn’t matter much. Don’t know if the 4 dr version would be the same. Mine works well for mounting my ski rack in the winter.

lakesinai · Sep 9, 2024

Mtea said:
I installed a wireless remote electric hoist in a steel channel for taking off my 2dr roof (parts cost about $270). The Trailrax half-rack seemed to be attached pretty well and I didn’t really want to take it off so I built a frame out of 1” square steel tubing (1/8” wall thickness) to facilitate attachment to the roof rack (1x4’ piece, 2x2’ pieces, a few 3/8” eye bolts). I was also afraid of damaging the seals on the roof using straps to go underneath as I’ve seen some do. A little trial and error finding the right balancing point and I can lift the roof off and slide it away.

I don’t know what Trailrax thinks of this, but it seems strong enough and certainly is less hassle than taking off the half-rack. Use your own judgement, but I’m happy with it for now. Question: Will the roof keep its shape hanging this way?

I have to say that my 2.3 BB 2dr non-sas auto feels like it has even more zip with that load off the back.

I've had my Trailrax Half-rack on for 2 years, never gotten around to taking it off. IF I was interested in removing my rear cap regularly, I would do exactly what you are doing, use the Rack for lifting points.

I instead installed a Besttop Sky Rider, so I have no intention of removing either . . . Until I change my mind!

From my experience, both the cap and the rack are very well built, and attach to each other very securely. I think this is an excellent idea! I can't see how the static load of suspending it mid-air in a garage is more stressful than the dynamic load of driving 80mph on a highway over a two year period. IME.

Ford Bronco Trailrax half-rack used for hoisting 2-door hardtop roof (w/ remote electric hoist) 20231003_124220

Ford Bronco Trailrax half-rack used for hoisting 2-door hardtop roof (w/ remote electric hoist) 20231012_152110

rws · Sep 9, 2024

Mtea said:
I installed a wireless remote electric hoist in a steel channel for taking off my 2dr roof (parts cost about $270). The Trailrax half-rack seemed to be attached pretty well and I didn’t really want to take it off so I built a frame out of 1” square steel tubing (1/8” wall thickness) to facilitate attachment to the roof rack (1x4’ piece, 2x2’ pieces, a few 3/8” eye bolts). I was also afraid of damaging the seals on the roof using straps to go underneath as I’ve seen some do. A little trial and error finding the right balancing point and I can lift the roof off and slide it away.

I don’t know what Trailrax thinks of this, but it seems strong enough and certainly is less hassle than taking off the half-rack. Use your own judgement, but I’m happy with it for now. Question: Will the roof keep its shape hanging this way?

I have to say that my 2.3 BB 2dr non-sas auto feels like it has even more zip with that load off the back.

I've been noodling an approach like this for my 4-door full rack TrailRax. I just keep measuring, staring a little bit, looking some more but currently, it still sits atop the Bronco with the rear portion of the roof in place.

I know my hoist can handle the load, I just need to determine how I keep everything balanced. on top of it all, I have the RackPax also, just for that added bit of complexity.
Well done for taking the initiative to solve a problem! I'll share once I finally decide how I'm gonna tackle the 4-door full rack situation.

Iamthedan1989 · Sep 9, 2024

I support my 2dr rear shell with the top only aswell. Havent had any issue yet

Seacat · Sep 9, 2024

I'm doing the same thing with my Turn Offroad Top, gets delivered next week. I built this hoist with full intention of some long term summer storage. The Turn Top rear section is one fiberglass piece (not multiple pieces like the OEM top) so I'm not worried about separation.

Wraithracing · Sep 10, 2024

Cool setup and great idea. I am considering doing a similar setup with my RCI roof rack. My thoughts were, that adding some flat 1/4-3/8" plywood strips or just 1X4 or 1x6 underneath the bottom of the rack and then using some flat ratchet straps to anchor those to the roof rack would mitigate any stress on the top itself hanging by the roof rack alone. So essentially a thin light wood frame that mimics the Bronco body where the roof would normally sit on. Then anchors from there to the roof rack or even the hoist assembly for additional support. Adds minimal weight to the whole setup and provides at least some sort of added protection to the roof structure. Your opinions may vary.

Trailrax half-rack used for hoisting 2-door hardtop roof (w/ remote electric hoist)

Mtea

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RagnarKon

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Mtea

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RagnarKon

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Fly

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Tilzbow

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Bschurr

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Mtea

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Offroad Newb

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Mtea

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lakesinai

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rws

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Iamthedan1989

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Seacat

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