We used it the other weekend, fine. Been packing this weekend ready for France very early on Thursday morning and one of the struts has snapped off. It was not overful or overloaded.
We rang the Roofbox company and funnily enough they knew straight away what we were on about, so I wonder how many other complaints they have had?
Fortunately we can still use it, but it does make opening the lid a bit more difficult, and seeing it is on top of a Freelander, it's not the easiest thing to reach!
Same problem with our box. Both struts have popped at various times. Nothing to do with overloading. It's a design fault, as the strut flexes laterally when opening or closing, and the elbow joint in the centre is not designed for this.
I didn't bother going back to the retailer, as any replacement would still suffer from the fault.
Permanent fix, as suggested on this site a few weeks ago, is to insert a nut and bolt through the elbow to prevent the joint from popping. Ten minutes for each, and no problems since.
Apart from this, the box itself is a cracker. Easy to fit, easy to close, and holds a massive amount.
Just brute force, I'm afraid. A third hand would come in handy too, to keep the hydraulic strut retaining pin in place while pressure is applied to the fitting.
If I'd had one, I would have used a long clamp, or a vice with really wide opening jaws.
Thinks - you could try using one of those pump things that squirt bathroom type sealant out of tubes. But brute force is probably just as effective and quicker.
We have had the same fault with our huskey roof box, i went to the local nut and bolt shop and bought 2 4mm bolts about 40mm long and 4no penny washers with 2 lock nuts.
This has cured the fault. As mulligrubs stated, we never sent it back to kamei as they would send the same design out.
I'm afraid you have to use brute force to get the hydraulic arm back into position.
When i get home this evening i'll post up the picture of the new and improved strut !!
Good luck.
Thanks acce1arator, we'd already spoken to The Roofbox Company who sent two replacement struts without question, so they are used to this. But now we can see the pics, we are going to have a go and adapt ours. Fortunately it worked fine whilst we were away, but it could happen again.