Foam Washer
Foam Washer
Side Rail (track)
End Cap
Neoprene
Washer
#10-24x 1.25”
#10-24x 1”
Cap Core
Retainer Washer
Propeller Tee Nut
1/4” Stainless Steel Flat Washer
#10-24 Lock Nut
Cover
Core Area Installation
Single Layer Installation
INST-TC-UV (2 of 2) 130201
4. Slide Tie Down Loops into rails (see illustration to right) and position in center of rails
5. Slide Stanchions onto side rails, positioning them between mounting holes.
6. Tighten adjustment knobs sufficiently to hold stanchion in place but loose enough to allow rails to swivel to conform to cap
roof contour.
Rack Installation:
DO NOT
remove tape liner on PVC roof slats until step 4.
1. Position roof rack and PVC slats in desired location on cap roof. Allow rails to rotate in stanchions to match roof contour.
Tighten adjustment knobs securely. Mark location of rack and slats.
2. Remove rack and slats. Recheck location to insure that mounting fasteners will penetrate through core area of roof a minimum
of 1" inside or outside the outer edges of core area, based on desired mounting location relative to core area.
3. Clean roof where slats will be applied using an adhesive prep solution such as Pro Bond, Tite-R-Bond or denatured alcohol.
Roof surface MUST be free of dust, dirt, wax, oil, etc. to insure proper tape adhesion.
4. Remove tape liner from bottom of slats, place in position and press firmly over the length of the slats. DO NOT allow tape to
contact roof surface until slats are in desired position.
5. Reposition rack in desired location. Beginning with pre-drilled holes nearest each end of each rail, select/use a minimum of 4
holes in each rail that will provide equal spacing between the fastener positions. Drill 3/16" holes thru all roof layers. inserting
machine screws as holes are drilled to prevent rack from moving as remaining holes are drilled.
6. Install 3/16 " self-adhesive foam washers on bottom of rail end caps (see illustration below). Place end caps flush against ends
of rails. Hold in place and drill 3/16" hole through all roof layers. If installing outside core area, proceed to Step 10 now.
7. From inside truck cap, use 9/32" drill bit to ream out all drilled holes through the inner fiberglass layer only! NOTE: If the
cap has a fabric liner glued to inside of roof, place a long nail or screw down through mounting holes to aid in locating drilled
holes in liner.
8. Assemble propeller Tee nuts and retaining washers with flange side of washer down and toward floor of truck bed and barrel
of Tee nut toward roof (See illustration above). Press barrel of Tee nuts into the 9/32" holes until flush with roof.
9. Insert #10-24x1" machine screws down through holes and roof at each end of side rail and screw into tee nuts, using minimal
downward pressure to prevent forcing tee nuts out of holes. Be sure each machine screw has a neoprene washer, and that the
underside of each side rail end cap and rail hole being utilized has a foam washer installed.
Do not overtighten,
as excessive
screw torque may damage fiberglass layers or core material and/or force neoprene washers from under screw heads. Use of
a liquid thread lock on machine screws is recommended. For end caps, repeat this procedure using #10-24x11/4" machine
screws. Proceed to Step 11 now.
10.
Installing outside core area or roof thickness under 1/2":
(Two people required for this step) Insert #10-24x1"machine
screws down through rails. Place 1 1/8" retainer washer against inside of roof, followed by 1/4” Stainless Steel flat washer
and 1/4” lock nut (See illustration above). Tighten securely.
Do not overtighten,
as excessive screw torque may damage
fiberglass layers or core material and/or force neoprene washers from under screw heads. For end caps, repeat this procedure
using #10x24x11/4" machine screws.
11. Snap black plastic screw covers onto retaining washers (Break away any excessive screw shank flush with top of tee or lock
nut if necessary to enable plastic screw cover to snap on to retainer washer).
12. Position crossbars in desired location and tighten adjustment knobs securely.
Operating Instructions:
To adjust crossbar position, rotate adjustment knobs 2 to 3 full turns counter-clockwise. Slide
crossbars to desired position and rotate knobs clockwise firmly to securely lock crossbar stanchions in place (periodically
check knobs for tightness). To remove crossbars, rotate adjustment knobs 4 to 5 full turns counter clockwise and press
inward on knobs while lifting stanchions off rails. Reverse procedure to re-install crossbars.