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

INDS-TC-OE 2 of 2 120918
INSTALLATION:
1-Place roof rack 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. Position self-adhesive roof slats in desired location (Do not remove tape liner
from slats at this time!) Mark location of roof rack and slats.
2-Remove rack and verify marked location relative to core area as detailed in Step 1. Remove slats and clean roof area
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 adhesion of slats.
3-Peel liner from tape on bottom of slats and carefully place slats in desired location, pressing firmly in place. Do not
allow tape to contact roof surface until slats are in desired location.
4-Reposition rack in desired location. Secure with masking tape to prevent shifting. Using side 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. Note: If mounting outside core area
or in surfaces less than 1/2" thick, proceed to Step 10 now.
5-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.
6-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 (Fig 2). Press barrel of Tee nuts into 9/32" holes until flush with roof.
7-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 and/or core material. Use of a liquid "thread lock" on machine
screws is recommended. Insert screw hole covers (plugs) in end holes of rail end stanchions.
8-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.
9-Position Crossbars in desired location and tighten adjustment knobs securely.
For installing outside core area or in surfaces less than 1/2" thick (Fig.1); this method requires two people in most
instances:
10-Install 2" machine screws down through rails, insuring that neoprene washers are seated under screw heads.
11-Place retaining washer with flange side of washer down toward floor of truck bed.
12-Place 1/4" Stainless Steel Flat Washer against bottom of retaining washer.
13-Install #10-24 Lock Nuts on Machine Screws and tighten securely.
14-Remove excessive screw length. Snap black screw covers onto retaining washers, and insert screw hole covers (plugs)
in end holes of rail end stanchions.
15-Position Crossbars in desired location and tighten adjustment knobs securely.
#10-24 Machine Screws w/neoprene
washers under heads
End Stanchion
3/16” x 1/8 “ Foam Washers
Rail
Assembly & Core Installation
3/4” Cube Foam Block
Outer Fiberglass Layer
Inner Fiberglass Layer
“Core” Area
Propeller Tee Nuts/Retainer Washers/Covers
Neoprene Washer
Crossbar
#8 Blunt-End Screw
Side Rail
End Stanchion
#10-24 x 2" Machine Screw
Foam Washers
Assembly & Single-layer Installation
Crossbar Connector
Lock Nut
Retainer Washer
Cover
S. Steel Flat Washer
Fig. 2
Fig. 1