4 plastic inserts broke off and I've already spent about 1.5 hours on clearing out the first one. Has anyone come up with a decent method of getting them out? I've drilled, screw extractor, drove a screw into it etc.
You could replace the rail studs and then reseal them.
When I installed my rack, I sheared off 2 of those plastic inserts and spent a lot of time trying to get those plastic bits out. Andy from Voyager Racks suggested replacing the rail studs rather than trying to clean them out (thanks for the help!!).
You have to cut through the sealant around the studs and then they can be removed. I used an exacto knife to do it. I then used clear RTV to seal in the replacement studs.