Perrycraft DynaSport Fiberglass Mounting Hardware Kit - Manual

(Over)
Neoprene Washer
Crossbar
#8 Blunt-End Screw
Side Rail
End Stanchion
#10-24 x 2" Machine Screw
Foam Washers
Crossbar Connector
#10-24 Machine Screws w/neoprene
washers under heads
End Stanchion
3/16” x 1/8 “ Foam Washers
Rail
3/4” Cube Foam Block
INDS-TC-UV Page 1 of 2 140529
Roof Rack & Roof Rails
Universal Mounting Hardware for Installation on Fiberglass/Composite Surfaces
& Sheet Metal Roofs Without Headliners
This hardware must be used in conjunction with several parts from the standard DynaSport rack or rail hardware
kits. Please note that some steps on this instruction sheet apply to roof racks only (such as crossbar assembly, roof slat
installation, etc.), and are not applicable to roof rail installations. This hardware kit may also be used for bolt-thru
installations in vehicles without headliners.
WARNING: Do not use sheet metal screws to attach roof racks or rails to fiberglass or composite materials or vehicles
with sheet metal roofs without headliners. External roof racks or rails do not increase the GVWR of the vehicle. Total
occupant and cargo load should not exceed the vehicle manufacturer's rated vehicle capacity. Maximum load for this rack or
rails is 75 lbs. evenly distributed on the crossbar assemblies. Maximum weight of loads placed directly on the roof slats (if
applicable) is dependent on the particular vehicle roof material and construction. Large or flat items such as plywood panels
or small water craft can trap air and cause wind lift. Extreme caution should be used when transporting such items, taking
into consideration road conditions, vehicle speed, load securement methods, etc. Molded car top luggage carriers (pods) should
be placed on the vehicle roof between the rack crossbars (if applicable) and secured directly to vehicle body. Perrycraft, Inc
cannot and does not assume responsibility for improper rack or rail installation, exceeding rack load limit, load securement
methods, vehicle roof strength, wind lift or any other factors beyond its control. NOTE: All fasteners, adjustment knobs and
load securements should be checked frequently.
Hardware Contents: 14/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, 1/4” Stainless Steel Flat Washers;
24/ea. - 3/16" x 1/2" x 1/8"Foam Rubber Washers; 4/ea. - 3/4" x 3/4" x 3/4" Foam Rubber Blocks. (Shorter racks without
center post will not require all fasteners included)
Tools required: Hand drill, 3/16 drill bit (2 1/2" or longer) and 9/32 drill bit, Phillips Screwdriver.
CAUTION: FAILURE TO PROPERLY INSTALL ALL SEALING WASHERS COULD RESULT IN WATER DAMAGE
TO TRUCK CAP AND/OR VEHICLE CONTENTS.
NOTE: For installing in fiberglass caps without hollow core roofs, mounting outside core area, in vehicle roofs less than 1/2”
thick, or sheet metal roofs without headliners, substitute #10-24 Lock Nuts and Stainless Steel Flat Washers (included, shown
in diagram “Single Layer Installation” on Page 2 of this Instruction Sheet) for the Propeller Tee Nuts. For roofs exceeding
1" in thickness, substitute #10-24 stainless steel Machine Screws in a proportionately longer length (not included) in place of
the 2" Machine Screws in conjunction with the propeller tee nuts as shown in “Core Installation” on Page 2.
Prior to assembling roof rack or rails check the curvature of side rails and crossbars relative to the curvature of cap roof or
vehicle roof. Rail and crossbar curvature can be adjusted by applying moderate hand pressure at necessary points with
rail/crossbar ends resting between two solid points. If roof rack or rails has center support post on side rails (longer racks/rails
only) it is critical that rails closely match the cap roof contour to avoid excessive tension on fasteners.
SIZING: For fiberglass or composite truck cap or lid installations, prior to assembling rack or rails, measure the size of the
"core" area of the cap roof. If mounting inside the core area (thicker 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 (thinner area), position
so that mounting hardware penetrates a minimum of 1" outside edges of the thicker 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.
2- Apply self-adhesive foam rubber washers around holes on
bottom of side rails.
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.