Perrycraft DynaSport Roof Rail OE Fiberglass Hdwr - Manual (Page 2)

Minimum 1”
Note: Drawings show use of
fasteners, seals, etc. from our
optional Fiberglass Mounting Kit. Single-Layer Mounting
(Outside Core Area) Core Mounting
Minimum 1”
Note: Drawings show use of
fasteners, seals, etc. from our
optional Fiberglass Mounting Kit. Single-Layer Mounting
(Outside Core Area)
Core Mounting
Propeller Tee Nuts/Retainers/Cover Washers
#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
S. Steel Flat Washer
Lock Nut
Retainer
Washer
Cover Cap Core
INDS-TR-OE 2 of 2 120918
INSTALLATION:
1-Place rails in desired mounting location on cap or lid and verify
location relative to core area of cap or lid interior, insuring mounting
fasteners will penetrate core area a minimum of 1" inside or outside
the outer edges of the core, depending on positioning preference.
2-Using rails as a template, drill 3/16" holes completely through roof
beginning with the middle hole of each end stanchion. Place a machine screw in each middle hole as drilled to prevent
shifting rail position. Drill remaining holes. Remove rails and clean away any chips or debris from drilling from under
rails. Reposition rails over drilled holes. If mounting outside core area or in surfaces less than 1/2" thick, proceed
to Step 8 now.
3-From inside of cap or lid using 9/32" drill bit, ream out all drilled holes through the inner fiberglass layer only. Note: If
truck cap has a liner glued to inside of roof, place a long nail or screw down through the mounting holes to aid in
locating drilled holes in liner.
4-Assemble propeller Tee nuts and retaining
washers with flange side of washer down
toward floor of truck bed and barrel of Tee
Nut toward roof. Press barrel of Tee nuts
into 9/32" holes until flush with roof.
5-Install 2" machine screws down through rails
using minimal downward pressure to prevent
pushing Tee nuts out of bottom holes (insure
neoprene washers are positioned correctly
under each screw head). DO NOT OVER TIGHTEN!
Excessive screw torque may damage fiberglass
layers or core material, and may force neoprene
washers from under screw heads. Use of a liquid "thread lock" on machine screws is recommended. Insert screw hole
covers (plugs) in end holes of rail end stanchions.
6-Snap black screw covers onto retaining washers. If excessive screw shank (over 1/4 ") extends from bottom of Tee nuts
it will be necessary to remove the excess to properly install screw covers.
7-Install PVC rail inserts by inserting both ends into rail and into cavity in end stanchion, then working toward center of
rail.
For installing outside core area or in surfaces less than 1/2" thick; this step
requires two people in most instances (see rail drawing above, substituting
fasteners shown to right and detailed below):
8-Install 2" machine screws down through rails, insuring that neoprene washers
are seated under screw heads.
9-Place retaining washer with flange side of washer down toward floor of truck bed.
10-Place 1/4" Stainless Steel Flat Washer against bottom of retaining washer.
11-Install #10-24 Lock Nuts on Machine Screws and tighten securely.
12-Remove excessive screw length. Snap black screw covers onto retaining washers, and insert screw hole covers (plugs)
in end holes of rail end stanchions.
13-Install PVC rail inserts by inserting both ends into rail and into cavity in end stanchion, then working toward center of
rail.