Perrycraft DynaSport Roof Rail OE Fiberglass Hdwr - Manual

INDS-TR-OE 1 of 2 120918
Roof Rails & Truck Bed Rails
For Installation on Fiberglass or Composite Truck Caps or Lids
WARNING: Do not use sheet metal screws to attach rails to fiberglass or composite material panels! These Roof/Truck
Bed Rails are designed for bolt-through installation only. If the rails are 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 rails. 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 both rails and other attachment points on the vehicle body. PERRYCRAFT, Inc. does not assume responsibility for
style or size of rails installed, improper rail 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, Snap-in PVC rail inserts, 1 – Hardware
bag containing: 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. - #8 x 5/8" Pan Head Self-tapping Stainless screws, Screw Hole Caps (plugs),
and 3/4" x 3/4" x 3/4" Foam Rubber Blocks, 2/ea. Rail Center Support Posts; 1- Instruction Sheet, Warranty/Consumer
Information Card.
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” rails are 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 cap or lid in the
approximate location to be installed. The curvature of the rail should approximate the cap or lid contour. If the rail is under-
curved and there is more than a 3/16” space between the ends of the rail and the cap or lid, or over-curved and there is more
than a 3/16" space between the center of the rail and the cap or lid, “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.
ASSEMBLY:
1-Apply self-adhesive foam rubber washers
around holes on bottom of side rails.
2-Compress and insert foam rubber blocks
into the rectangular hollow area in ends
of side rails.
3-Apply self-adhesive foam rubber washers
to bottom side of all mounting holes in
molded end stanchions and support posts.
4-Place 3/16" neoprene washer on 2" machine
screws, seating washers under screw heads.
5-Slide End Stanchions onto ends of rails.
Press center support posts onto bottom of rails at mounting holes.
#10-24 x 2”
Machine Screws
End Stanchion 3/16” x 1/2” x 1/8” Foam Washers
3/4” Cube
Foam Block
Inner F’glass Layer
3/16” x 1/2” x 1/8”
Foam Washers
Side Rail
Outer F’glass Layer
Core” Area
(over)
Increase Rail Bow Decrease Rail Bow