Tuffy Security 147 - Manual (Page 2)

Page 2 of 3 - 1/28/2008 – Rev122006
o Unbolt the passenger side OEM rack tubing and drill a hole in the vehicle roof under the center of
the tubing. Make sure the hole will be large enough for all the wiring, connectors and sealant to
be applied.
o Drill a hole on the inside of the passenger side OEM rack tubing so the wire harness can be
routed directly into the tubing from the light bar and down through the hole drilled in the roof of the
vehicle.
o Install the light bar as instructed below then finish these steps.
o Route the wires through the holes drilled into the vehicle. Tape or use grommets to protect the
wiring where it is routed through the drilled holes to prevent electrical problems.
o Inside the vehicle route the wires behind the windshield frame cover and behind the dash to
where the switches will be mounted and make all the wire connections according the instructions
that came with the lighting system to be mounted. Zip tie any slack behind the dash.
o Completely seal both holes using a silicone sealant or another comparable product/method.
o Reattach the interior covers and roof rack bolts.
• A non-drilling method involves routing the wires through the passenger door then behind the windshield
frame cover and dash to where the switches will be mounted. Things to consider: Large wiring
harnesses may not be easy to conceal on the roof and may create gaps in the seal where they enter the
vehicle therefore creating leaks.
• Another non-drilling method that may be a little cleaner involves routing the wires along the roof rack
tubing (or inside) then through the rear door. It would then need to be routed behind the interior covers
and or carpet to where the switches will be mounted. Things to consider: Some light systems will not
support longer wiring than what comes with them or the entire wiring harness will need to be replaced
with a larger gauge wire. Large wiring harnesses may not be easy to conceal on the roof and may create
gaps in the seal where they enter the vehicle therefore creating leaks.
2. Route wiring harness shown as #4.9 (not-included) through any of the 7 holes in the #2 Light mounting
bracket to the lights (not-included). Use grommets, tape or silicone sealant to protect the wires from the metal
edge to prevent electrical problems. (See Figure 1 - The #4.2 & #4.1 lights, #4.9 wire harness, and #4.4
hardware should be included with the lighting system and are only shown for illustration. A wide variety of
lighting systems and light mounting options are available.)
3. Route the wiring harnesses along the backside of #2 Light mounting bracket then place #3 Wire harness tray
bracket over wiring assembly so it is completely concealed. (See Figure 1)
4. Fasten all the lights to any of the 7 mounting spots on the #2 Light mounting bracket and the #3 Wire harness
tray bracket. Try aiming the lights at this point; it may be more difficult to adjust some lighting systems after
the assembly is mounted to the roof rack. (See Figure 1)
5. Place the light bar assembly in the final mounting position. Finish routing, connecting, and sealing the wire
harness at this point. Consult the lighting system manual for instructions. (See Figure 2)
6. Fasten the light bar assembly to the OEM roof rack tubing as illustrated using (2) #1 Clamp brackets, (8) 5/16-
18 x 1 ¼ button head cap screws #4.8 with (8) 5/16” USS Washers #4.5 (Wide OD), (8) 5/16-18 Nylock nuts
#4.7 with (8) SAE Washers #4.6 (Narrow OD). (See Figure 2)
NOTE: If the light bar assembly is being mounted with the Tuffy part #146 Roof cargo rack storage box
already installed the fairing location may need to be adjusted for the light bar assembly to clear.
NOTE: The light bar assembly can also be mounted on the horizontal portion of the OEM roof rack tubing by
instead fastening through the slotted mounting holes on the horizontal portion of the #2 Light bar bracket.
(Not illustrated)