Perrycraft DynaSport Roof Rack OE Fiberglass Hdwr - Manual

INDS-TC-OE 1 of 2 120918
Roof Rack
For Installation on Fiberglass or Composite Truck Caps and Lids
WARNING: Do not use sheet metal screws to attach Roof Racks to fiberglass or composite material panels! If this rack
is to be used to secure loads to a truck cap or lid, keep in mind that torque applied to any straps, cords, etc. between the load
and the vehicle body effectively add "load weight" to surface on which the rails are installed. Large or flat items such as
plywood or watercraft can trap air and create wind lift, thereby putting substantial upward pressure on the rack. Bulky or tall
loads can create tremendous horizontal wind resistance from headwinds and crosswinds. Extreme caution should be used when
transporting such loads, taking into consideration road conditions, vehicle speed, crosswinds, load securing methods, etc.
Large, bulky, tall or flat objects should be properly secured to the roof rack and other attachment points on the vehicle body.
PERRYCRAFT, Inc. does not assume responsibility for style or size of roof rack installed, damage resulting from use
of this Roof Rack to secure loads, improper rack installation, load securement methods, mounting surface strength,
wind lift or any other factors beyond its control. All load securements should be checked frequently and tightened as
necessary.
Contents: 4/ea – Side Rail End Stanchions, 2/ea – Aluminum Extruded Side Rails, Crossbars; 1 – Hardware bag containing:
12/ea. - #10-24 x 2" Pan Head Stainless Machine Screws, #10-24 Propeller Tee Nuts, 1 1/8" Retainer Washers with Snap on
Caps, 3/16" x 3/8" x 1/32" Neoprene Washers, #10-24 Nylock Nuts, Stainless Steel Flat Washers; 20/ea. - 3/16" x 1/2" x 1/8"
Foam Rubber Washers; 4/ea. - #8 x 1/2" Pan Head Blunt-End Stainless screws, Screw Hole Caps (plugs), and 3/4" x 3/4" x
3/4" Foam Rubber Blocks; 1/ea - Instruction Sheet, Consumer Information/Warranty Card. Note: Racks 65" and longer contain
2/ea Center Support Posts, additional 2" Machine Screws, Tee Nuts, Retainer Washers/Snap-on Covers, Neoprene and Foam
Washers, Nylock Nuts, and Stainless Steel Flat Washers.
Tools required: Hand drill, 3/16 drill bit (2 1/2" or longer) and 9/32 drill bit, Phillips Screwdriver, hammer, pliers.
CAUTION: Failure To Properly Install ALL SEALING WASHERS Could Result In Water Damage To Truck
Cap/Lid and/or Contents.
NOTE: For fiberglass caps and lids without sandwiched core roofs or if installing outside core area, substitute #10-24 Lock
Nuts and Nylon washers (included) for the Tee Nuts. For core areas exceeding 1" in thickness, substitute #10-24 Stainless
Machine Screws in a proportionately longer length (not included) for the 2" Machine Screws.
Before Installing: As this DynaSport “universal” roof rack is designed to fit several different applications, the “bow/curvature”
of the side rails may or may not exactly match the roof contour of a particular vehicle. The rails should be “dry fit” to the cap
or lid before installing. Carefully place one of the rails (without end supports or center support posts) on the vehicle roof in
the approximate location to be installed. The curvature of the rail should approximate the roof contour. If the rail is under-
curved and there is more than a 3/16” space between the ends of the rail and the vehicle roof panel, or over-curved and there
is more than a 3/16" space between the center of the rail and the vehicle roof panel, “bench adjusting” the curvature of the rails
is required. Adjust by suspending the rail between two points (4x4 wooden blocks, two tables, etc). To increase the curvature,
start with the rail upside down; to decrease the curvature, start with the rail right side up (see appropriate illustration below).
With hands spaced shoulder-width apart, apply sufficient pressure to the rail to increase or decrease the curvature as desired.
Repeat this process for both rails.
Important Note: While made of extruded aluminum, the rails are heat-treated for added strength. Therefore, several applications
of adequate "springing" pressure may be required to modify the curvature of the rails.
SIZING: Prior to assembling rack, measure the size of the "core" area of the cap roof. If mounting inside the core area, side
rails should be positioned so that mounting hardware penetrates the core a minimum of 1" in from edges of core. If mounting
outside core area, position so that mounting hardware penetrates a minimum of 1" outside edges of core area.
RACK ASSEMBLY:
1- Insert crossbar connectors into ends of crossbars and secure with #8 x 1/2 blunt-end self-tapping screws through
holes in underneath side of crossbars as shown in Fig. 1 on Page 2 of this instruction sheet.
2- Apply self-adhesive foam rubber washers around holes on bottom of side rails as shown in Fig. 2 on Page 2.
3- Compress and insert foam rubber blocks into the rectangular hollow area in ends of side rails.
4- Apply self-adhesive foam rubber washers to bottom side of all mounting holes in molded end stanchions and support
posts if included.
5- Place 3/16" neoprene washer on 2" machine screws, seating washers under screw heads.
6- Slide crossbar connectors into side rails positioning crossbars approximately 10" from ends of rails.
(Over)
Increase Rail Bow Decrease Rail Bow