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Well I just got through installing the Putco Boss locker rails.. For all of you who are interested they look awesome, but there method of attaching to the truck is not worth a !?$# !!! I would be scared to tie anything valuable to them. I have tightened the bolts all the way down even to the point where one bolt ran out of thread and they still wiggle when you pull on them.... You would think for $260 you could lift the rear end of the truck with them. They definitely need to come up with a better way to secure them to the bed that rubber gasket that expands as you tighten is impossible to make sturdy !!
I put the regular lockers on my XLT and love them. When I first put them on, I had the same problem. When I tightened them down, it buckled the plastic bed rail caps (because of the gap between them and the top of the bed rails) and they didn’t feel solid (also because of the gap…couldn’t draw down tight). Anyway, I took them back off, and cut pieces of 1/8” metal scrap I had around the garage (can buy at Lowes or Hope Depot) and used them as shims between the caps and the bed. I used four small pieces in each pocket hole (one on each side). Then, I reinstalled the lockers and tightened them down. Now, with solid mounting points, mine are rock solid.
They should really include shims with the lockers with this type of mounting set-up for the new f-150s…don’t know why they don’t.
I am going to give the company a call on Monday and let them know that i am completely dissatisfied with this. I can see where your shim idea could change the outcome a bunch. the only problem with taking them back off now is that the one i tightened down to much will not come back out, it is tightened down past the threads and will not budge one way or the other Grrrrr!!!! The local truck specialty shop took a look at it and said i would have to drill the bolt head off and order an new connection set up from Putco, so it looks like i am stuck with it the way they are. I am going to recommend that they rethink there way of mounting for the new Ford's with the plastic bed rail covers and need to include some type of spacer like you are describing.. I should have followed your instructions closer from your last post, live and learn.
I agree that Putco should really have come up with better mounting for this. They had to have experienced this when they made the kit. Maybe if they hear from some unsatisfied customers, they may reconsider and include better mounting hardware for future customers.
As far the the one bolt you cant get out...drilling may be tough to do. If you decide you want to try to take it out, I would try just tightening the heck out of it and hope that it snaps the bolt (I broke one of my bolts the first time I installed mine...it broke more easily than I figured it would. I was following the 65 foot pound in the instructions and "snap!"). If that doesn't work, then drilling may be the next option. Replacement bolts were hard for me to find in stainless. I did finally find one at a regular bolt shop in Newport News VA that handles specialty hardware.
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