SHERPA THE BEAR PAW 48 Inch Roof Rack Instruction Manual
- October 30, 2023
- SHERPA
Table of Contents
SHERPA THE BEAR PAW 48 Inch Roof Rack
HARDWARE CHECKLIST
Exact hardware color counts may vary based on the options selected at checkout.
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10 3/16” Rivets
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24 1/4”-20 (1”)
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8 M8 (16mm)
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12 1/4”-20 (9/16”)
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6 1/4”-20 (1/2”)
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8 M8 Flat Washer
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46 1/4” Fla Washer
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18 1/4” Tnut
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4 Carriage bolt 1/4-20 x1”
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4Nylock nut 1/4”-20
BEFORE YOU BEGIN
The installation of this rack requires you to drill into your roof. If you are not comfortable with this, please contact a reputable installer.
USING TNUTS
FAIRING ASSEMBLY
Required Components:
6x 1/4”-20 x 1/2”
6x 1/4” Flat Washers
6x Tnuts
Drop 6 tnuts into the slots on the cross member and line them up with the holes in the fairing. Secure with 6 bolts and washers
MOUNT ASSEMBLY 01
Required Components:
8x M8 x 16 Hex bolt
8x M8 Flat Washers
2x Rivet Spacer – Contour
2x Rivet Spacer – Flat
Loosely fasten the supplied rivet spacers to the bottom (longer) flange of the mounting brackets using the supplied M8 hex bolts and M8 flat washers. The contour spacers go on the front mounting brackets, and the flat spacers go on the middle mounting brackets. The brackets are designated with ‘F’ and ‘M’, respectively
MOUNT ASSEMBLY 02
Required Components:
4x 1/4-20 x 1” Carriage bolt
4x 1/4-20 Nylock nut
4x Flat washer
2x Adj. bracket – top
2x Adj. bracket – bottom
Assemble the adjustable pressure mounting brackets as seen in the diagram. Note that the bottom part (with the pre-assembled rubber pad attached) has square slots that the carriage bolts will sit in.
Leave the nuts on the back side of the mount assemblies loose. Once on the vehicle, these mounting brackets will be adjusted to apply pressure in the gutter to keep the rack rigid.
This rear pressure mount was designed to avoid drilling into the roof in the 2G/3G Tundras where it would interfere with OEM brackets for the airbags
MOUNT ASSEMBLY 03
Required Components:
8x 1/4”-20 x 9/16”
8x 1/4” Flat Washers
8x 1/4” Tnuts
Secure the tops of the mounting bracket pairs to the wide faces of the cross members using the supplied T-nuts, 9/16” hex bolts, and flat washers.
Leave the hardware that attaches the mount to the crossbar loose. This will make it easier when placing the rack on the truck later.
Once on the vehicle, the rack can be centered by measuring the distance from the end of the cross member to the inside-edge of the mounting bracket on either side of the vehicle.
SIDEPLATES
Required Components:
8x 1/4”-20 x 1”
8x 1/4” Flat Washers
Fasten the sideplates to the ends of the two mounting-foot cross members using the supplied 1” socket buttons and flat washers in the designated mounting slots, as pictured above. Recall that the brackets come in pairs denoted by the ‘F’ (front) or ‘M’ (middle). Note the small notch in the bottom corner of the bracket – this will face toward the front of the vehicle when installed.
The rearmost slot is used for the adjustable pressure mounting brackets that were assembled in Mount Assembly 02.
The cross member should sit relatively centered in the slot, but may shift slightly due to small variations in roof construction or shifting during the drilling step. More on that later.
TEMPLATE
Remove the trim from the roof gutter. Position the assembled rack on the roof of your vehicle. Move the mounting brackets along the cross members so that the rivet spacers sit centered in the gutters of the roof.
Adjust the brackets along the length of the cross member so that the rivet
spacer sits flat and is relatively centered in the gutter. Likewise, the
bottom edge of the sideplate should fit nicely along the curvature of the
vehicle with a consistent gap of around 1/2”. If it does not, move the rack
(or cross members in the slot) until the rack
looks centered and placed properly.
The properly aligned rack will serve as the drilling template. Follow the next steps to ensure the best fitment of the rack.
Adjust
With the assembled rack resting on the vehicle, adjust the rear pressure mounting brackets so that the rubber pad sits flat and centered against the surface of the roof gutter. Increase the height of the brackets until the bottom edge of the sideplate aligns with the
curvature of the roof. These brackets may require an additional adjustment – after riveting down the front and middle mounting brackets to the roof – in order to relieve or increase pressure. The rear brackets should support the rack but not cause the rack to rake forward. If the middle mounting bracket pair is not sitting flat against the gutter surface during the rivet step, loosen the rear adjustable set.
THE NEXT STEPS ARE CRITICAL AND ARE CONSIDERED AN EXPERT LEVEL INSTALL. IF YOU ARE NOT COMFORTABLE DRILLING PLEASE FIND A LOCAL SHOP TO INSTALL YOUR RACK.
DRILLING
Required Tools:
1x Center Punch
1x 13/64” or #8 Drill Bit
With the rack on the truck, mark the position for each rivet spacer USING A PUNCH to create your starting points for drilling. This is important as the drill bit will want to walk away while drilling your pilot holes. The position of these holes are important in making sure that the rack fits your vehicle correctly. Measure 3 times, check 4 times. Be extremely careful not to drill through your airbags – using a drillstop on your drill bit can help prevent this by limiting the travel of the drill bit.
With the holes marked, the rack can be removed from the roof. It is worth double checking that the rack sits in its final configuration before marking, removing, and drilling. The rivet spacers can also be removed from the mounting brackets on the rack to assist the following steps.
Once you have your drilling points marked with the punch, drill the hole using a 13/64” or #8 sized drill bit. A pilot hole using a smaller drill bit – such as a 1/8” or 5/32” bit – can be drilled first. DO NOT allow the drill bit to plunge after the hole is drilled. The headliner is only a small distance below the surface of the roof. Be sure to keep the drill bit as straight as possible while drilling. AGAIN, DO NOT allow the drill bit to plunge after the hole is drilled.
Check that the rivets will pass through the rivet spacer and the drilled hole. A tight fit is preferred in order to solidify the connection between the vehicle and the rack.
RIVETS
Required Components:
8x 3/16” Rivets
1x Rivet Tool
Next, secure the rivet spacers using the holes you have drilled. It is important that the spacer is tight against the roof and free of debris before riveting it down. Apply a small amount of silicone in and around the rivet spacer and rivet to seal up the hole in the roof. Using your rivet tool, clamp down on the rivet as close to the head as possible. The mandrel of the rivet will shear off once it is installed and should be flush with the head.
WE RECOMMEND PLACING THE FULL RACK BACK ON THE ROOF FOR THE REMAINING STEPS. IMAGES ARE SHOWN WITHOUT SIDES FOR ILLUSTRATIVE PURPOSES.
MOUNTS
Required Components:
12x M8 Bolts
12x M8 Flat Washers
Next, re-install the assembled rack on the roof, allowing the mounting brackets to rest on the rivet feet. If these do not line up, loosen the hardware that secures the mounting bracket to the cross member and adjust as needed. Fasten the mounting bracket to the rivet spacer using the M8 x 16 hex bolt and washers with the addition of a drop of blue threadlocker on the bolt threads supplied with the rack.
Once satisfied with how the rack sits on the vehicle, tighten down all hardware between the cross members and the mounting brackets. The rack should not need adjusting after this step.
CROSS MEMBERS
Required Components:
8x 1/4”-20 x 1” Socket buttons
8x 1/4” Flat washers
2x 53” Cross members
Secure all of the remaining cross members to the rack system using the 1” socket buttons and washers in the open slots in the sideplate. Position according to your load requirements
All products built and designed by Sherpa Equipment Company are intended for
off-road use and should be assembled, installed, and used according to Sherpa
Equipment Company’s recommendations. Sherpa Equipment Companies products
should be used safely with good judgment towards others and surroundings.
By installing Sherpa Equipment Companies products on your vehicle you assume
all liability. Sherpa Equipment Company will not be held liable for damages or
loss associated with the installation or use of its products. It is
recommended that you inspect your roof rack within the first 100 miles of
installation and every 500 miles after.
