Perrycraft DynaSport Fiberglass Mounting Hardware Kit - Manual (Page 2)

#10-24 Machine Screws w/neoprene
washers under heads
End Stanchion
3/16” x 1/8 “ Foam Washers
Rail
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
Single-layer Installation
Crossbar Connector
Lock Nut
Retainer Washer
Cover
S. Steel Flat Washer
INDS-TC-UV 2 of 2 140529
INSTALLATION:
1-Fiberglass/composite cap or lid installations: Place roof rack or 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. Position self-adhesive roof slats
in desired location (Do not remove tape liner from slats at this time!) Mark location of roof rack or rails and slats.
Single-layer vehicle installations: Place roof rack or rails in desired mounting location. Position self-adhesive roof slats
in desired location (Do not remove tape liner from slats at this time!) Mark location of roof rack or rails and slats.
2-Remove rack or rails and verify marked location relative to core area as detailed in Step 1 (if applicable). 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 or rails in pre-marked 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,
in surfaces less than 1/2" thick, or sheet metal roofs without headliners, 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 1). 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, in surfaces less than 1/2" thick, or sheet metal roofs without headliners; 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 vehicle or 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.
OPERATING INSTRUCTIONS: To adjust crossbar position, rotate
adjustment knobs 2 or 3 full turns counter clockwise. Slide crossbars to
desired location and rotate adjustment knobs clockwise firmly to secure
crossbars in position. Periodically check adjustment knobs for tightness.