Review: Pelican Cargo BX135 Roof Box Quality Tested

Embarking on an adventure often means grappling with limited storage space. Whether it’s for camping gear, tools, or recovery equipment, finding a secure, weatherproof solution that withstands the rigors of the road is paramount. This is where dedicated cargo solutions like the Pelican Cargo BX135 come into play, offering a robust alternative to traditional roof boxes. Designed for durability and versatility, this case promises to keep your valuables protected, organized, and accessible, whether mounted on your vehicle’s roof, tucked in a truck bed, or stowed in an SUV.

What is a Roof Box? Why Do You Need One?

At its core, a roof box is an enclosed storage container designed to be mounted on a vehicle’s roof, typically on a roof rack system. Its primary purpose is to expand a vehicle’s cargo capacity, freeing up interior space for passengers and improving comfort on long journeys. Common uses range from family vacations and camping trips, where extra luggage, tents, and sleeping bags are needed, to carrying specialized equipment like skis, snowboards, or fishing gear. For off-road enthusiasts or professionals, a roof-mounted solution can secure recovery gear, tools, and supplies, keeping dirty or bulky items out of the main cabin.

While traditional roof boxes are often sleek, aerodynamic units, the Pelican Cargo BX135 stands out as a heavy-duty cargo case that excels in environments where resilience is key. It serves the same fundamental need—to add secure, external storage—but with an emphasis on extreme protection against impact, dust, and weather, making it suitable for demanding conditions beyond standard highway travel. Choosing a roof box or a durable cargo case like the BX135 enhances convenience, protects your gear from the elements and theft, and keeps your vehicle’s interior tidy and spacious for occupants.

Popular Roof Box Types on the Market

The market offers a diverse range of roof boxes, categorized by their material, size, and design, each catering to specific needs and preferences. Understanding these distinctions helps in appreciating the unique positioning of the Pelican Cargo BX135.

By Material

Roof boxes are typically constructed from various materials, influencing their durability, weight, and cost. Common materials include ABS plastic, fiberglass, and sometimes metals. ABS plastic is widely used for its balance of impact resistance, flexibility, and affordability, often forming the shell of aerodynamic boxes. Fiberglass offers greater rigidity and can be molded into more complex, often sleeker, shapes, providing a premium feel and enhanced aerodynamics, though it can be more brittle on impact. Metal options are rare for full boxes but sometimes used for specialized, heavy-duty cargo carriers or tool boxes.

The Pelican Cargo BX135 distinguishes itself with roto-molded polyethylene construction. This manufacturing process creates a single, seamless, and incredibly strong shell that is highly resistant to impacts, punctures, and harsh environmental conditions. Unlike thinner plastics or fiberglass, roto-molded polyethylene offers superior structural integrity, making the BX135 exceptionally durable and reliable for extreme outdoor adventures or demanding professional use. This material choice is a testament to its design for heavy-duty applications, where protection is prioritized over aerodynamic aesthetics.

By Size and Volume

Roof boxes come in a wide array of sizes and capacities, measured in liters (L) or cubic feet (cu ft), to accommodate different vehicle types and storage requirements. Smaller boxes, typically ranging from 200-300L, are ideal for compact cars or short trips, carrying softer items like bags and coats. Medium-sized boxes (300-500L) are versatile, suiting most family cars and adventures, often fitting skis or camping gear. Larger boxes (500L+) are designed for substantial carrying needs, perfect for large families, extensive camping setups, or specialized sports equipment.

The Pelican Cargo BX135 offers a substantial internal volume of approximately 97 liters (or 3.44 cubic feet). With interior dimensions of 36.80 x 12.25 x 13.20 inches (93.5 x 31.1 x 33.5 cm), it provides ample space for a variety of gear. This capacity is well-suited for organizing and securing tools, recovery equipment, cooking supplies, camera gear, or even multiple dry bags of clothing. Its specific dimensions allow it to fit neatly across truck beds, between wheel wells in some SUVs, or securely on a roof rack without excessive overhang, offering a practical storage solution for specialized items rather than bulky, general luggage.

By Style and Design

The design of a roof box significantly impacts its performance and convenience. Many traditional roof boxes feature aerodynamic profiles, tapering towards the rear to reduce wind noise and drag, which can improve fuel efficiency. Key design features include dual-side opening for easy access from either side of the vehicle, quick-mount systems for tool-free installation, and integrated locking mechanisms for security.

The Pelican Cargo BX135 prioritizes rugged functionality over sleek aerodynamics. Its rectangular, robust design is built for maximum protection and utility. It features heavy-duty, E-coated steel latches that are strong and corrosion-resistant, ensuring a secure closure even in challenging environments. The case also includes tie-down plates for additional securing options and robust lay-flat handles for easy lifting and carrying. While it lacks the tapered, aerodynamic shape of many roof boxes, its construction and features are optimized for extreme durability, weather resistance, and security, providing peace of mind that your contents are safe from both the elements and potential theft. The roto-molded construction itself, combined with an EPDM O-ring, ensures the case is dustproof and weather-resistant, a crucial design aspect for protecting sensitive gear.

Key Features and Specifications: Pelican Cargo BX135

The Pelican Cargo BX135 is designed for those who demand uncompromising protection and organization for their gear. Here’s a detailed look at its essential features and specifications, highlighting what makes this cargo case a standout choice for rugged adventures:

Feature	Specification	Benefit
Construction Material	Roto-molded Polyethylene	Extreme impact resistance, seamless, dustproof, weather-resistant, superior durability.
Exterior Dimensions	41.00″ L x 17.25″ W x 16.00″ H (104.1 x 43.8 x 40.6 cm)	Optimal size for roof racks, truck beds, or SUV interiors; balances capacity with vehicle fit.
Interior Dimensions	36.80″ L x 12.25″ W x 13.20″ D (93.5 x 31.1 x 33.5 cm)	Ample space for diverse gear like tools, recovery kits, camping supplies, or photography equipment.
Internal Volume	97 Liters (3.44 cu ft / 5,919 cu in)	Significant storage capacity for essential items without being overly bulky.
Weight (Empty)	28.70 lbs (13 kg)	Manageable weight for installation and removal, contributes to vehicle roof load limits.
Latches	E-coated Steel, Double-Throw Latches (x3)	Secure closure, corrosion resistance, tamper deterrence. Can be locked with padlocks (sold separately).
Handles	Heavy-Duty Lay-Flat Handles	Comfortable and durable for lifting and carrying, tucks away for compact storage.
Sealing	EPDM O-Ring Seal	Ensures a dustproof and weather-resistant seal, protecting contents from moisture and particles.
Mounting	Mounting Kit Interface Plate (Mounting kits sold separately)	Versatile mounting options for roof racks, truck beds, or cargo areas; secure attachment points.
Temperature Range	-20°F to 140°F (-29°C to 60°C)	Reliable performance in extreme hot and cold climates.
Warranty	Limited Lifetime Guarantee (on the case itself)	Assurance of quality and manufacturer support for the lifespan of the product.
Key Use Cases	Transporting photo/video gear, tools, clothing, food, camp supplies, off-road recovery equipment securely.	Designed for demanding outdoor adventures and professional applications requiring robust protection.

Pelican BX135 Cargo Case securely mounted on a vehicle roof rack, designed for rugged outdoor use

Buying Guide: How to Choose the Right Roof Box

Selecting the perfect roof box, or in this case, a robust cargo solution like the Pelican Cargo BX135, requires careful consideration of several factors. Your choice should align with your specific needs, your vehicle’s capabilities, and the nature of your adventures.

Determine Your Needs

Start by asking yourself what you intend to carry and where you will be going. Are you planning family road trips with extra luggage, or embarking on off-grid overlanding adventures requiring specialized gear and tools? The quantity, size, and type of items you need to transport will dictate the necessary capacity. For soft bags and general luggage, a traditional roof box might suffice. However, if you require extreme protection for sensitive equipment, dirty recovery gear, or heavy tools that might get jostled on rough terrain, a rugged cargo case like the BX135 is a superior choice. Consider also the frequency of use – an occasional trip versus constant, heavy-duty deployment.

Choose Material and Size Suitable for Your Vehicle

The material of your cargo solution impacts its durability and weight. For the Pelican BX135, its roto-molded polyethylene construction offers exceptional resilience against impacts and harsh weather, making it ideal for challenging environments where standard plastics might crack. When considering size, remember that the cargo case should not impede your driving visibility or exceed your vehicle’s dimensions significantly. The BX135, with its exterior of 41.00 x 17.25 x 16.00 inches, is designed to fit a variety of roof rack systems, truck beds, and SUV cargo areas. Always check your vehicle’s roof load capacity, including the weight of the roof rack and the cargo case itself, to ensure safe operation. The BX135’s empty weight of around 28.70 lbs (13 kg) should be factored into this calculation.

Consider Convenient Features

Modern cargo solutions offer features that enhance security, ease of use, and protection. For the BX135, look for its E-coated steel latches, which provide a secure closure and can be padlocked for added theft deterrence. The integrated tie-down plates are also invaluable for further securing the case to your vehicle, preventing movement during transit. While the BX135’s lid stay system is sold separately, it’s a worthwhile accessory for hands-free loading and unloading. Weather resistance and dustproofing are critical, especially for off-road use, and the BX135’s EPDM O-ring seal ensures your contents remain dry and clean through various conditions.

Research Brands and User Reviews

Investing in a reputable brand like Pelican, known for its long-standing reputation in protective cases, provides assurance of quality and reliability. Look for manufacturers offering comprehensive warranties, such as Pelican’s limited lifetime guarantee on the BX135 case. Reading user reviews and testimonials can offer real-world insights into the product’s performance, common fitment scenarios, and any potential downsides. Pay attention to feedback regarding ease of installation, durability under specific conditions, and overall satisfaction to make an informed decision.

Compare Prices and Find a Reputable Seller

Prices for high-quality cargo cases like the Pelican BX135 can vary. It’s wise to compare costs from several authorized dealers to find the best value. Remember that mounting kits are often sold separately, so factor this into your total budget. Purchasing from reputable retailers ensures you receive an authentic product, benefit from warranty support, and have access to reliable customer service. Verify the seller’s return policy and shipping options before finalizing your purchase.

Installation and Safe Use of a Roof Box

Proper installation and adherence to safety guidelines are crucial when using any roof-mounted cargo solution, including the Pelican Cargo BX135. Following these steps ensures your gear is secure and your travels are safe.

The first step is to install your vehicle’s roof rack system correctly, if you don’t already have one. Ensure it is rated for the combined weight of the cargo case and its contents, adhering to the manufacturer’s specifications. Once the roof rack is securely in place, prepare the Pelican BX135 for mounting. This involves attaching the appropriate mounting kit (sold separately) to the integrated interface plate on the case. There are specific mounting kits designed for roof racks or cross-bed truck mounts.

Secure the BX135 onto your roof rack or truck bed. Follow the instructions provided with your mounting kit precisely. Typically, this involves aligning the case, attaching clamps or bolts to the roof rack bars, and tightening them evenly until the case is firmly secured and shows no movement. Double-check all attachment points to ensure they are tight and properly engaged.

When loading the BX135, distribute weight evenly within the case to maintain vehicle balance and stability. Place heavier items at the bottom and center, directly over your vehicle’s roof bars, and lighter items towards the ends. Avoid overloading the case; always respect the maximum weight capacity of both the cargo case and your vehicle’s roof. For the BX135, its rugged construction allows for dense packing of tools and gear, but the total load must remain within safe limits. Use internal straps or bags to prevent items from shifting during transit, which can affect vehicle handling.

Regular inspection and maintenance of your Pelican BX135 and its mounting hardware are vital. Before each trip, check the mounting bolts and clamps for tightness. Inspect the case itself for any signs of damage, and ensure the latches are functioning correctly and the EPDM O-ring seal is clean and free of debris to maintain its weather-resistant properties. Periodically clean the case with mild soap and water to remove dirt and grime.

Hands securing heavy-duty Pelican BX135 Cargo Case onto a truck bed mount with robust latches and tie-down plates

Important Notes When Using a Roof Box

Using a roof-mounted cargo solution like the Pelican Cargo BX135 requires a few key considerations to ensure safety, efficiency, and compliance with regulations. Being mindful of these points will enhance your travel experience and protect your investment.

Firstly, be aware of the altered driving dynamics of your vehicle. The added weight and wind resistance on the roof can affect handling, especially at higher speeds or in crosswinds. While the BX135 is not as aerodynamically streamlined as some roof boxes, its sturdy form factor still presents an increase in profile. Always adhere to recommended speed limits for vehicles carrying roof loads, which are often lower than standard highway limits. Drive defensively, allowing for increased braking distances and smoother turns.

Secondly, pay close attention to your vehicle’s increased overall height. The Pelican BX135, when mounted on a roof rack, will add significant height. This is crucial for navigating low-clearance areas such as car parks, garages, drive-throughs, and tunnels. Always know the exact height of your vehicle with the cargo case installed and watch for clearance signs. Even a slight miscalculation can lead to costly damage to both your vehicle and the cargo case.

Furthermore, perform a thorough check before every journey. Even short trips can be impacted by loose fittings. Verify that the Pelican BX135 is securely fastened to its mounting system, and all latches are fully engaged and locked. Ensure that the contents inside are properly secured and distributed to prevent shifting. This pre-trip inspection is a small investment of time that can prevent significant problems on the road.

Finally, consider fuel efficiency. Any item mounted on the roof will inevitably increase aerodynamic drag, leading to a reduction in fuel economy. While the BX135 is designed for utility rather than aerodynamics, minimizing its time on the roof when not needed can help reduce fuel consumption. Pack efficiently to avoid unnecessary bulk and remove the case when not in use for extended periods.

Conclusion

The Pelican Cargo BX135 is more than just a roof box; it’s a heavy-duty, roto-molded cargo case engineered to provide uncompromising protection and secure storage for your most valuable gear. Its robust polyethylene construction, E-coated steel latches, and weather-resistant seal make it an ideal choice for adventurers, outdoor enthusiasts, and professionals who demand durability and reliability in challenging environments. While it may not offer the sleek aesthetics of traditional aerodynamic roof boxes, its utility-focused design excels in safeguarding contents from impacts, dust, and moisture, whether mounted on a roof rack, in a truck bed, or within an SUV. Choosing the Pelican BX135 means investing in peace of mind, knowing your essential equipment is protected regardless of where your journey takes you. Are you ready to elevate your gear protection to the next level?

Frequently Asked Questions

What is the primary difference between the Pelican Cargo BX135 and a traditional roof box?

The Pelican Cargo BX135 is a heavy-duty, roto-molded cargo case primarily designed for rugged protection and durability, featuring robust materials and latches. Traditional Roof Boxes are typically more aerodynamic, made from lighter ABS plastic or fiberglass, focusing on streamlined aesthetics and reducing drag for general luggage transport. The BX135 prioritizes extreme weather and impact resistance.

Can the Pelican Cargo BX135 be permanently mounted on my vehicle’s roof?

Yes, the Pelican Cargo BX135 is designed with a mounting kit interface plate that allows it to be securely attached to most vehicle roof racks, or even directly to truck bed mounting systems. However, the necessary mounting kits are sold separately, allowing you to choose the specific mounting hardware that best suits your vehicle and desired installation location.

Is the Pelican Cargo BX135 truly waterproof?

The Pelican Cargo BX135 is described as “weather-resistant and dustproof” thanks to its roto-molded construction and EPDM O-ring seal. While it offers excellent protection against rain, splashes, and dust ingress, Pelican typically uses “weather-resistant” rather than “waterproof” to indicate its high level of protection without guaranteeing submersion resistance like some of their hard cases. It’s highly effective for keeping contents dry in harsh weather.

What kind of items are best suited for storage in the Pelican Cargo BX135?

Given its robust construction and secure design, the Pelican Cargo BX135 is ideal for storing sensitive electronics, camera equipment, tools, camping supplies, recovery gear (such as straps, winches, or shackles), dry food, and clothing. Its protective qualities make it perfect for items that require safeguarding from impacts, dirt, and moisture during demanding travel conditions.

What is the weight capacity of the Pelican Cargo BX135?

While the case itself weighs approximately 28.70 lbs (13 kg), its internal volume is 97 liters. The maximum weight capacity for its contents will depend on the strength of the case itself, and more importantly, the load capacity of your vehicle’s roof rack system and the vehicle manufacturer’s recommendations. Always consult your vehicle and roof rack manuals for maximum permissible load limits.