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post #1 of 33 (permalink) Old 03-17-2015, 08:12 PM Thread Starter
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Unhappy Drilling tour pak lid for luggage rack

For those of you that have done this before, I need some advice before I do mine. I just received my tour pak I ordered from Horny Toad HD. I got the Air Wing tour pak lid rack that I need to mount on it. The instructions with the rack say to set the rack on top of the TP lid and center it and mark around where the mounts touch the lid. Then put masking tape over those spots and mark again on the masking tape, then drill with a small bit first and then drill again for the final size hole. I'm so anal about stuff like this that I'm not sure I'll get it exactly centered the way I want doing it this way. On the inside of the lid there are already marks that are centered and line up perfect for the rack. Is there any way I could drill from the inside using a very small bit without flaking or cracking the paint on the outside and then finish drill with the final size bit from the painted side? This would really hurt my feelings if I screwed this up.

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post #2 of 33 (permalink) Old 03-17-2015, 08:17 PM
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If you set the rack on the inside of the lid and it lines up perfectly on the existing marks I would say you lucked out and should be ok using those for a drill guide.

Tape over the outside where the holes will come thru, the OEM paint holds up pretty well and should be fine.


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Last edited by RoadHawg; 03-17-2015 at 08:19 PM.
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post #3 of 33 (permalink) Old 03-17-2015, 08:27 PM
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I drilled mine out from the painted side down (just like directions state) Used masking tape, and brand new bits. Take your time and it will come out fine. Mine looks factory installed. Good luck!
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post #4 of 33 (permalink) Old 03-17-2015, 08:55 PM
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^^^ What they said. Use good sharp bits and don't run it wide open. Higher heat from the bit = the plastic melts around the hole and is a pain to clean


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post #5 of 33 (permalink) Old 03-17-2015, 09:04 PM
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Careful...

I just did this, and used the inside markings. It "fit" but was snug and in hindsight, I should have just followed the directions (marking the top of the lid with the rack and drilling holes). I felt like when I screwed in the bolts, I was very close to cracking the lid, as they did not line up exactly. Lucky it turned out ok for me, but still would not recommend my method.

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post #6 of 33 (permalink) Old 03-17-2015, 09:06 PM
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post #7 of 33 (permalink) Old 03-17-2015, 09:32 PM
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Try using a step bit, they work great. I used them to install spoilers to the trunks of brand new cars..they start out small, stepped to larger size as desired..tape, set, mark, measure from all sides, square up, double check (by eye) from all angles, drill, mount..ride!! Good Luck!!

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post #8 of 33 (permalink) Old 03-17-2015, 10:49 PM Thread Starter
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Thanks for all the replies. Always nice to be able to get advice from people that have already done what you're about to do.

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post #9 of 33 (permalink) Old 03-17-2015, 11:00 PM
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Either way it's nerve racking. Drilling through paint just ain't right. haha Measure twice (or 4 or 5 times) before drilling.

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post #10 of 33 (permalink) Old 03-18-2015, 12:12 AM
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I set the rack on the lid to get an idea of where to put the masking tape , then I put a wide piece of tape at each corner .. Then I measured and eyeballed three or five times , once satisfied , took a ball point pen and drew a circle around each leg , then drilled a small hole in the center of each circle , then a larger hole and wala , mine may be off a sixteenth of an inch from being spot on , but you would have to really look hard to tell it ..

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