WEATHER GUARD Model 210-3 Safari Van Rack - Manual

10-24 Nylon Lock Nut
1/4-14 x 3/4
Self Drilling
Screw
1/16" Hole
3/8-16 Nylon
Lock Nut
Cushion Strip
3/8" Flat
Washer
3/8-16 x 1-1/4"
Carriage Bolt
Tie Down
10-24 x 2-3/4" Flat Hd. Screw
7/32" Hole
3/8-16 x 3/4"
Thrd. Cut
Bolt
Air Foil
ASSEMBLY INSTRUCTIONS
1. Assemble the Rail Halves. Be sure to include Cushion Pad between the halves.
2. Note: Gutter widths on the Chevy GMT-600/GMC Savana vans are narrower. If installing
this rack on one of these vans, 3-1/2" will need to be cut off of each crossmember.
3. On a Crossmember, attach the Air Foil. Center the Air Foil on the Crossmember, mark
each hole location, drill the marks with a 1/16" drill bit, then fasten.
NOTE: If using a drill driver, it is unnecessary to drill the holes for the self-drilling screws.
Figure 3. Placement Dimensions
Driver Side Rear/
Passenger Side
Front Rail
Figure 2. Safari Rack Assembly
Crossmember
with Wear
Strip
Stand
Center Stand
Center Stand
Adjusting Plate
5/16" Flat
Washer
5/16-18 Nylon
Lock Nut
Clamp
Cushion Strip 5/16-18 x 1-1/4"
Carriage Bolt
5/16" Flat Washer
and 5/16-18 Nylon
Lock Nut
5/16-18 x 2-1/4"
Carriage Bolt
CAUTION
To keep debris out of your eyes when drilling, wear protective eyewear.
4. Insert the Crossmembers into the sockets on one rail assembly. Be sure the Air Foil faces
forward.
5. Slide the other rail assembly onto the Crossmembers with the Crossmembers fully into the
sockets.
6. Assemble the Front and Rear Stands. Loosely fasten the Front and Rear Mounting Stands
to the side rail assemblies, as the Stands will have to be adjusted on the vehicle.
7. If installing the rack on a Ford Econoline or a GMT-600/GMC Savana van, (see Figure 2
Inset) the Center Stand will be bolted to the Center Stand Adjusting Plate through the bottom
holes [B], to compensate for the upward bow in the center of the gutter. Secure. If installing
the rack on Chrysler or older Ford or GM vans, the top holes [A] will be used. Attach the cen-
ter stand assembly to the rails.
8. Cut Cushion Strip into 8" lengths and press onto the underside of the six Stands where the
Stand will rest in the gutter.
5/16" Flat Washer
and 5/16-18 Nylon
Lock Nut
5/16-18 x 3/4"
Carriage Bolt
5/16-18 x 1-1/2"
Carriage Bolt
5/16-18 x 3/4"
Carriage Bolt
Rail
Support
INSET
Rail
Support
A
B
NOTE: The Ford Econoline and GMT-600/GMC Savana vans have an upward bow in the
center of the gutter. When installing the rack, we suggest using the dimensions shown in Fig-
ure 3. All measurements are from center to center of the stands. The van rack placement on
the roof can vary somewhat, but the dimensions (shown in Fig. 3.)must be held.
9. With the help of others, place the rack on the vehicle. Make sure the mounting Stands are
all resting in the gutter. Adjust the Stands so both sides match each other. Driver Side Front/
Passenger Side
Rear Rail
WARNING
Ladders must be secured per ANSI standard A142.2-1990 paragraph
8.4.4. Ladder damage will occur from road shock and vehicle vibration if
the ladder is not properly secured to the ladder rack. Bouncing and side
to side motion of a improperly secured ladder will cause wear and
weaken the ladder. Using a damaged ladder could lead to a structural
collapse and could result in a serious injury or death.
Ladder Strap
NOTE: STEPS 10-13 ARE FOR GM VAN INSTALLATION ONLY. IF YOU ARE NOT IN-
STALLING RACK ON A GM VAN, SKIP TO STEP 14.
10. Due to excess body caulk in some gutters on GM vans, it may be necessary to place a
1/4" thick spacer in between the Stand and the Clamp. The stand must contact the Van roof
gutter as shown in Figure 4.
11. Using a ruler or tape measure, measure the distance from the Stand to the outer edge of
the gutter (See Figure 4). If this dimension is greater than 5/8" of an inch, a 1/4" Spacer will
need to be installed. In extreme cases, a portion of the caulk might have to be cut out of the
gutter and then re-caulked after the rack is installed.
12. If a spacer is not required, (dimension measured is 5/8" or less) skip step 13 and install
the Clamps as shown in Figure 2.
13. If a 1/4" Spacer is required, install the Spacer between the Stand and the Clamp as
shown in Figure 5.
14. Fasten the Stand Clamps to hold stands to the gutter (see Figure 2.). Tighten all nuts.
Tighten the vertical bolt so the Clamp is drawn up firmly under the rain gutter. Tighten the
horizontal bolt. Recheck all rack bolts to be sure they are tight. At the end of the first week of
use, check all fasteners for proper tightness and then every three months thereafter.
Figure 4. Measure
caulk thickness
Gutter
Stand
GM Van
Roof
Caulk
Measure this
distance. If
greater than
5/8" a Spacer
is required.
Figure 5. Install 1/4" Spacer between
Stand and Clamp if dimension mea-
sured is greater than 5/8"
1/4" Thk.
Spacer
5/16-18 x 1-1/4"
Carriage Bolt
5/16" Flat
Washer and
5/16-18 Nylon
Lock Nut
5/16" Flat
Washer and
5/16-18 Nylon
Lock Nut
5/16-18 x 1-1/2"
Carriage Bolt
GM Van
Roof
Part No. 24-0220 REV. B ECN 5315 05/13