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Let's Go Aero BLACK BOX, Product Manual

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Let's Go Aero BLACK BOX Product Manual Download Page 2

PAGE 2 OF 21

A

B

C

D

E

F

G

H

I

J

1

2

1

1

1

1

2

1

2

1

FLATPIPE™ SPINE

RETAINER CLIP

5/8” SILENT HITCH PIN®

HAND-TIGHTEN PIN

5/8” LOCK WASHER

5/8” PLASTIC BUSHING

5/8” SPRING NUT

WAX

RUBBER BUMPER

5/8” FLAT WASHER

FLATPIPE™ PLATFORM

QTY.  DESCRIPTION

NOTE: End Tubes [X] and four (4) Square End Caps [DD] are for open rack (GearCage) assembly only. You may save 

these parts for future use or discard them. See GearCage Rack assembly manual for open rack assembly. 

RACK PARTS LIST & ASSEMBLY OVERVIEW

VV

WW

XX

YY

ZZ

AAA

BBB

CCC

DDD

EEE

FFF

GGG

HHH

III

JJJ

KKK

LLL

MMM  

NNN

AERFOIL COVER

BULKHEAD

BULK HEAD WITH HANDLE

1/4-20 JOINT SOCKET HEAD BOLT

1-4-20 PIN NUT (BLACK)

3.5” x 1/4” BOLT 

1/4” x 20 NYLOCK NUT

43” AERFOIL BAND  

BAND SPRING

LIFT PLATES

LIFT ARMS 

GAS SHOCKS

3/8” NYLOCK NUTS

7/8” SELF TAPPING SCREWS

10-24 x 1 SCREW

5/16” WASHER

10-24 NYLOCK NUT

1/4” SPLIT RING WASHERS

SUPPORT BAND

AERFOIL LID (Black Box Cover) 

S

T

U

V

W

X

Y

Z

AA

BB

CC

DD

EE

FF

GG

HH

3

2

4

2 

16

6

12

6

8

4

12

8

2

6

4

4

FLOOR PANEL

SIDE RAIL

U-TUBE

END TUBE (OPEN RACK ONLY)

8MM X 70MM BUTTON HEAD BOLT

6MM X 20MM BUTTON HEAD BOLT 

M6 WASHER

M6 NYLOCK NUT

6MM X 50MM BUTTON HEAD BOLT

6MM X 30MM BUTTON HEAD BOLT

PIN NUT

SQUARE END CAPS

FRAME BAR

K-LATH SELF TAPPING SCREW

SPACERS

PLUG

RACK & SIDE PANEL 

QTY.  DESCRIPTION

K

L

M

N

O

P

Q

R

2

2

4

8

18

18

2

1

FEMALE TUBES

FRAME ANGLES

HAT BRACKETS

M8 CARRIAGE BOLTS

M8 WASHERS

M8 NUTS

REFLECTOR CAPS

SAFETY CABLE 

TWINTUBE FRAME MOUNT

QTY.  DESCRIPTION

II

JJ

KK

LL

MM

2

2

1

1

4

8MM X 50MM BUTTON HEAD BOLT

SIDE PANEL

END PANEL WITH HINGES

END PANEL WITH PULL LATCHES

1/4-20 X 3/4 BOLT

RACK & SIDE PANEL

QTY.  DESCRIPTION

QTY.  DESCRIPTION

NN

OO

PP

QQ

RR

SS

TT

UU

2

1

2

2 

4

4

4

2

1

1

1

4

4

2

2

4

2

2

2

2

2

4

4

4

4

4

3

LED LIGHTS

WIRE HARNESS

LED LICENSE PLATE BRACKET

LED MOUNT BRACKET

6mm HEX BOLT

6mm NYLON NUT

6mm WASHER

REFLECTOR STRIPS

LIGHT KIT 

QTY.  DESCRIPTION

If you are missing any items, contact your sales 

agent if the product was assembled by them. If 

not, or if purchased from Let’s Go Aero, please 

contact us at 1-877-GO-4-AERO (464-2376).

Tools Needed:

1/2” Wrench and Socket

7/16" Wrench and Socket

5/32” Allen Wrench

10 mm Wrench

3/8in Wrench

7/8in Wrench

3/16” Allen Wrench

Center Punch

Drill and Phillips Bit

Phillips Screwdriver

Flathead Screwdriver

Summary of Contents for BLACK BOX

Page 1: ... SUPPORT LETSGOAERO COM READ THIS MANUAL THOROUGHLY BE SURE TO READ ALL WARNINGS BEFORE OPERATION Installation Safe Use Operation Highlights Fits 2 size receiver hitches Rated for 300 lbs of cargo payload 160 lbs empty weight Class II minimum tow rating required Class III recommended Parts Tools List 2 Installation 3 Open Closing Operation 19 Slide Out Operation 20 Warranty Registration 21 Descrip...

Page 2: ...Y 8MM X 70MM BUTTON HEAD BOLT 6MM X 20MM BUTTON HEAD BOLT M6 WASHER M6 NYLOCK NUT 6MM X 50MM BUTTON HEAD BOLT 6MM X 30MM BUTTON HEAD BOLT PIN NUT SQUARE END CAPS FRAME BAR K LATH SELF TAPPING SCREW SPACERS PLUG RACK SIDE PANEL QTY DESCRIPTION K L M N O P Q R 2 2 4 8 18 18 2 1 FEMALE TUBES FRAME ANGLES HAT BRACKETS M8 CARRIAGE BOLTS M8 WASHERS M8 NUTS REFLECTOR CAPS SAFETY CABLE TWINTUBE FRAME MOUN...

Page 3: ...re 2 Hitch Receiver Figure 3 STEP 2 TOOLS 7 8 SOCKET WRENCH Slide the shank end of the FlatPipe Spine A into the receiver hitch aligning the choosen mounting hole and Spring Nut G with the hole in the receiver hitch Figure 3 Secure the Spine with the Silent Hitch Pin C one 1 5 8 Lock Washer E and one 1 5 8 Flat Washer J by threading the Silent Hitch Pin into the Spring Nut Figure 4 NOTE The 5 8 Lo...

Page 4: ...ock in a safe place for future use A J Figure 7 K Figure 5 Figure 6 STEP 5 Install Female Tubes K over the waxed Flat Pipe A tubes Figure 9 NOTE The holes of both Female Tubes K should align with the holes on the FlatPipe Spine A tubes Figure 9 A K Figure 9 STEP 4 Insert the remaining Spring Nut G into either open end user choice of the FlatPipe Spine A tubes Align the Spring Nut G threading with ...

Page 5: ...the carrier can be slide rearward for rear hatch door access Figure 10 D K B G F Never operate vehicle without the Hand Tighten Silent Hitch Pin D sufficiently tighten to prevent the carrier from sliding while in transit Failure to do so may result in bodily injury and property damage WARNING STEP 8 Set one Frame Angle L on top of the Female Tubes K NOTE Be sure that this Frame Angles N shorter en...

Page 6: ...ill be required before final assembly O P R M The Safety Cable prevents the BlackBox Carrier from sliding off the FlatPipe Spine when telescoped The rack may be slid out when parked for vehicle hatch access only Never move the vehicle while the carrier is slid out Failure to engage the Safety Cable and follow product guidelines may result in bodily injury and property damage WARNING N L K Figure 1...

Page 7: ... L Figure 16 TOOLS 1 2 WRENCH 3 16 HEX KEY Lay two 2 Floor Panels S over the U Tubes U NOTE The third center Floor Panel S is not attached in the same manor as the two 2 Floor Panels in this step and should not applied at this time NOTE The holes in the Floor Panels S U Tubes U Frame Bars EE and Frame Angles L must align Connect the Floor Panels S U Tubes U and Frame Bars EE using eight 8 8mm x 70...

Page 8: ...rside of the carrier secure the center Floor Panel S to the Floor Panels from Step 12 using six 6 8mm x 20mm Button Head Bolts X twelve 12 6mm Washers Y and six 6 6mm Nylock Nuts Z Figure 18 Fully secured these connections STEP 13 X Y Z S U U S UNDERNEATH CARRIER VIEW Figure 17 Figure 18 TOOLS 7 16 WRENCH 5 32 HEX KEY ...

Page 9: ...ding the Bolts into the Pin Nuts CC Figure 21 Hand tighten only at this time CC T NOTCH END SLOT END STEP 14 U U JJ AA AA T CC AA Figure 19 Figure 20 Figure 21 Large Hole TOOLS 5 32 HEX KEY Insert one 1 Pin Nut CC into each of the four 4 remaining mounting locations at the tops of the outer U Tubes U in the same manor as Step 14 Figure 22 Drop one 1 6mm x 30mm Button Head Bolt BB in to each end of...

Page 10: ...Bolts through the over hanging edge of the End Panel the Spacers GG and through to the base of the End Panel threading the bolt through the Pin Nut on the interior of the Side Rail Figure 27 Fully secure this hardware W W W KK EE KK KK LL S U CC Figure 24 Before Figure 25 Figure 26 Figure 27 Figure 28 STEP 16 W W STEP 17 Locate two 3 16 dia holes in each end panel Using the End Panel KK LL as a gu...

Page 11: ...ghten pin NOTE Users wanting less clearance between the tow vehicle and carrier should position the Hat Brackets M closer to the vehicle on the Slide Tubes K Figure 31 DO NOT overlap the Hand Tighten warning sticker Once the final clearance adjustments have made confirm the aligned Female Tubes K are slid all the way back against the Rubber Bummers I and then fully secure all Hat Brackets M and ha...

Page 12: ...ut onto the back of the LED Lights and LED Mount Bracket NOTE The LED Light NN with the Green Wire must be installed on the Passenger side of the Vehicle FF T U Figure 33 Supplied LED Hardware TOOLS TWO 2 7 16 WRENCH OR SOCKET TOOLS 7MM WRENCH PHILLIPS HEAD SCREW DRIVER From underneath the carrier connect the quick link end of the Safety Cable R to the hole in the frame of the Flat Pipe Spine A Fi...

Page 13: ...reen Wire to the passenger side of the vehicle will result in mismatched stop turn lights and improper signaling WARNING RR STEP 24 OPTIONAL STEP 25 Secure user supplied License Plate to the License Plate Brackets PP using two 2 6mm Hex Bolts RR two 2 6mm Washers TT and two 2 Nylon Nuts SS Figure 36 Connect the Yellow Wire from the LED Lights NN on the drivers side to the Yellow wire on the LED Wi...

Page 14: ...ear the edge of the AerFoil Cover VV so the Bulk Head s cut line faces the interior of the carrier Figure 38 39 NOTE The BlackBox Logo on the face of the cover indicates the drivers side of the Aerfoil Cover Bulkhead WW MUST be placed on the drivers side Re Insert Joint Connector Bolts YY through the pre installed Pin Nuts ZZ and tighten Cut Line WW XX VV YY ZZ WW STEP 26 Remove backing and apply ...

Page 15: ...Shavings may fall from AerFoil lid during the unpacking assembly process These are a normal result of the manufacturing process and are knocked loose during shipment Latch Keeper Adjustable Pull Latch VV STEP 29 TOOLS 3 8 WRENCH PHILLIPS SCREWDRIVER DRILL 1 4 BIT NOTE This step will ne easiest is some assists you Place the AerFoil Lid on top of carrier bottom You should be able to engage the Adjus...

Page 16: ...emaining two 2 AerFoil Bands and Spring Lay the Band Spring assembly over the AerFoil Cover VV by bending the assembly around the top edge of the Aerfoil Cover with the padded side of the Bands placed against the Cover as shown Attached the Band Spring assembly by starting at removing one 1 Joint Connector Bolt YY from one corner of the Aerfoil Cover and then re thread the Bolt through the larger ...

Page 17: ...asher MMM for each plate Secure the Lift Plates to the carrier rail as shown Figure 49 NOTE Each Lift Arm FFF is marked A or B Lift Arm B must be installed on the side of the carrier that is closest to the vehicle Side A must be installed on the side of the carrier furthest from the vehicle Figure 50 Using the angled plates on each Lift Arm FFF attach the upper lid portion of both Lift Arms to the...

Page 18: ... patches from the Support Bands NNN One at a time remove the plastic film from the back of the velcro patches and apply the velcro patches as shown to the inside edge of the Aerfoil Cover Sheet VV evenly spaced in three sections across the lid as shown Figure 55 Insert the Support Bands NNN into the lid of the carrier attaching each end to velcro placed on the inside of the Aerfoil Cover The curve...

Page 19: ...e Handle and continue to close the lid using the Handle Engage both Quick Release Latches located on the passenger side to latch the lid in place Figure 58 Optional Run a pad lock customer provided threw each Quick Release Latch to lock the carrier Opening When opening the BlackBox release both Quick Release Latches located on the passenger side Using the handle lift don t throw the lid until the ...

Page 20: ...the vehicle until the holes for the Hand Tighten Pin D re align Re insert and fully thread the Hand Tighten Pin D Secure with Retainer Clip B Do not push or pull on the carrier lid Pushing or Pulling on the carrier lid during slide out in operation may cause warping of the lid over time Failure to follow proper lid care may result in damage to carrier damage to property bodily injury or death Alwa...

Page 21: ...shall be to replace such products or parts proved to be defective A Return Merchandise Authorization is required prior to return Please contact Let s Go Aero toll free at 877 464 2376 or 719 630 3800 or via email to support letsgoaero com to get an RMA number No warranty is given for LGA products purchased outside of the United States and Canada To register your product visit the Let s Go Aero web...

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