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Old 04-30-2012, 05:13 PM   #1
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Washers for ACE rails?

So I don't have a way to grind the washers to fit my ACE rails and I was thinking why don't I buy these:

Replacement Rectangular Washer for Thule Ride-On Adapter Thule Accessories and Parts 853-2154

rectangular washers!!

Do you think they would work?

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Old 04-30-2012, 05:19 PM   #2
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Old 04-30-2012, 05:20 PM   #3
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No dimensions, can't tell. Why don't you call Adam at ACE, explain your problem and see if he will ship you some washers with the flat ground on them.

Call before Noon, he seems to be in the shop in the morning.
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Old 04-30-2012, 05:21 PM   #4
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Or send to me, and I'll grind at work for a low low price of $4.99 plus shipping
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Old 04-30-2012, 05:21 PM   #5
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So much more work....
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Old 04-30-2012, 05:23 PM   #6
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15$ for an angle grinder? That will last about 2 minutes
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Old 04-30-2012, 05:23 PM   #7
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I already talked to Adam, that was a no go., I'll probably just end up buying my own grinder, never know when you'll need it.
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Old 04-30-2012, 05:24 PM   #8
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The washers are press-fit onto the bolts so removal will be challenging.

If you run out of options, talk to your local garage or metal shop and ask 'em how much they'd charge you to grind them down.

It's only like 1/4-inch on each side, so it isn't much really.

I was in the same position, with access only a bench grinder at work.
I obtained permission, removed the bolts one at a time, ground them, and re-installed them until I could install the rails.

Be creative. You'll find a way.

It's so worth it too. I've been complimented twice on my Ace rails.

Good luck!
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Old 04-30-2012, 05:24 PM   #9
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15$ for an angle grinder? That will last about 2 minutes

I can grind 4 washers in one minute.
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Old 04-30-2012, 05:25 PM   #10
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15$ for an angle grinder? That will last about 2 minutes
The job takes 1.5, leaving half a minute for the next job!

I have to admit I have that same grinder still in the box! (I purchased it afterward)

I'm not using it until I can find a 2 minute job of my own!
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Old 04-30-2012, 05:30 PM   #11
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use a vice if you can. Wear eye protection. Don't even think of using a dremel.
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Old 04-30-2012, 05:37 PM   #12
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use a vice if you can. Wear eye protection. Don't even think of using a dremel.

Yeah, dremel is out. I'll just go to lowes, or when I get my lift done I'll see if the installer can do it quick. I'll just mark them with a marker before I go.
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Old 04-30-2012, 05:41 PM   #13
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Yeah, dremel is out. I'll just go to lowes, or when I get my lift done I'll see if the installer can do it quick. I'll just mark them with a marker before I go.
You could use this as a launching point for putting some tools together for future mods.
I bought my lil' cheapie grinder with relocation of the vacuum pump in mind, for instance.
The bracket has to be removed to allow for some aftermarket accessories that can mount in that location (light bars, etc.), but other grinding duties will surely arise in the future.
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Old 04-30-2012, 05:45 PM   #14
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I was in the same position, so I bought a $30 grinder from Lowe's and opted to use a stainless steel cutting wheel...was so much more fun.

...and yes, don't even try using a dremel...F$%in thing will just throw a million sparks and not make a dent in that stainless steel beast of a washer.
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Old 04-30-2012, 05:48 PM   #15
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Harbor Freight has a 4 1/2 inch grinder for $9.99. You'll still need the grinding disc tho. I was too lazy to go get this and I did grind all 4 washer using a Dremel!!! took about 15 minutes each and many cut off discs.... it can be done with much patience!!!
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Old 04-30-2012, 05:54 PM   #16
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with much patience...and a fire extinguisher
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Old 04-30-2012, 06:24 PM   #17
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HackSaw and 1 min.
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Old 04-30-2012, 06:56 PM   #18
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I did it with an $8 hand file.
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Old 04-30-2012, 07:07 PM   #19
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go to Depot, get a sanding disk for your drill ($5 bucks) and a fiber cut off disk for metal (about another 5 bucks). Put the disk on your drill sander, the washer in a vise and then either use the edge to cut off the small section or use the flat part of the disk to grind it down. That's what I did, worked like a charm.
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Old 04-30-2012, 08:17 PM   #20
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I did it with an $8 hand file.
I bit it off
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Old 04-30-2012, 09:02 PM   #21
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Just use your finger nails.



A sawzall and a vice to hold the washer is an option.
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Old 04-30-2012, 09:12 PM   #22
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I bit it off
All you've got to do is stare at it just right and it will do what you want.

Edit: On a serious note (and because I feel guilty for not contributing) I bought five 4 1/2" grinders at Harbor Freight a few years ago for $6 each. 4 of them still work and I use two of them a day (one hard rock, one steel wire wheel). The one that doesn't work anymore burned up because I overused it. They do heat up rather quickly, but if I'm careful how I use them, they don't overheat.
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Old 04-30-2012, 09:14 PM   #23
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I bit it off
Now that's what I call a git er done attitude!
Don't forget to floss.
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Old 05-01-2012, 12:41 PM   #24
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I used me good ole Dremel tool, with a cutting disc.

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