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Roof Rack & Holes

From 2016 Ford Explorer “PIU” — documented by Steve83.

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2016 Ford Explorer - PIUs don't have luggage racks (which would make a great place to mount police lights without the paint damage caused by common light bars),… 2016 Ford Explorer - This '15 Ltd. was T-boned in the RHR door, so its roof rack was OK. So were its front heated/cooled seats, its center console/shifter, its… 2016 Ford Explorer - Because the factory drain holes are blocked by factory foam seals, several of the bolts were submerged & rusty, requiring extra effort to g… 2016 Ford Explorer - First thing was a thorough cleaning & inspection. 2016 Ford Explorer - The PIU has a short plastic filler bolted at the front, and then flexible rubber fillers held in by double-sided foam tape. Fortunately, af… 2016 Ford Explorer - It was very quick & easy to install. Now, for those antenna holes... 2016 Ford Explorer - This cheap duct tape has been on here long enough for the backing to separate from the adhesive & fibers more easily than from the paint. 2016 Ford Explorer - The tape was applied over the remains of a self-adhesive foam gasket. 2016 Ford Explorer - Some 3M Adhesive Remover and a sharpened SpitzNagel (pointy fingernail) plastic scraping tool eventually removed everything with minimal da… 2016 Ford Explorer - Some 3M Adhesive Remover and a sharpened SpitzNagel (pointy fingernail) plastic scraping tool eventually removed everything with minimal da… 2016 Ford Explorer - All the residue came up with paper towels, soap & water, and a little brake cleaner. But the paint/clearcoat has a permanent fog where the… 2016 Ford Explorer - These caps are sold for Ford Transit Connect van roofs, so I thought they'd be good here. Unfortunately, they're much smaller than I expect… 2016 Ford Explorer - After the sealant cured, the excess comes off fairly easily with the same SpitzNagel. 2016 Ford Explorer - This rubber plug barely fit into the 1 larger hole, but it still got sealed down. 2016 Ford Explorer - After all the sealant was cured, each hole was tested for several minutes. 2016 Ford Explorer - None of them leaked, so after some wiring mods, the headliner can go back in. 2016 Ford Explorer - There were a couple more holes than needed, so they were filled with some extra butyl sealant. 2016 Ford Explorer - This cheap copy set of crossbars is for '11-15 Explorer roof racks. The poor instructions show the steel nuts inserted wrong, so I had to f…