FVCO TR0102B 148 HR EXT Low Pro Roof Rack Installation Guide
- October 30, 2023
- FVCO
Table of Contents
FVCO TR0102B 148 HR EXT Low Pro Roof Rack
Product Information: Low Pro Roof Rack 148 HR EXT
The Low Pro Roof Rack 148 HR EXT is a product manufactured by Flatline Van Co. It is designed to be assembled and secured properly before attaching to your vehicle. The product comes with a set of tools, package contents, and a hardware pack. The package contents include driver front rail, driver rear rail, passenger front rail, passenger rear rail, crossbar, rail connecting bracket, driver rail fairing bracket, passenger fairing bracket, center fairing bracket, driver fairing bracket, passenger rail fairing bracket, landing pad, fairing gasket, fairing, sticker pack, and an installation guide. The hardware pack includes 1/4-20 flange head screw, 1/4 flat washer, 1/4-20 button head screw, 1/4 split lock washer, T-nut insert, 1/4-20 carriage bolt, 1/4-20 nylock, M8 hex bolt, sealing washer, and a 5/32 allen key.
Product Usage Instructions
- Attach the landing pads to the top of your van using the supplied M8 hardware and sealing washers. Due to factory inconsistencies, you may need to grind clearance on the holes of your van to gain access to the threaded holes.
- After tightening down the M8 bolts, apply a sealant and run a bead all the way around the landing pad where it seats to the van. The neoprene gasket seals the landing pad to the van body.
- Start attaching the side rails using the 1/4-20 carriage bolts, 1/4 flat washers, and 1/4-20 nylocks. Leave them a little loose to allow for movement when attaching the crossbars. Come back later to tighten all bolts.
- Once you’ve got all the side rails up, fasten the rail connecting brackets to the side rails using the 1/4-20 flange head bolts, 1/4 flat washers, and 1/4-20 nylocks. Align the side rails and butt them tight to each other as you tighten down the connecting bracket bolts.
- Place your crossbars in desired location, loosely bolting the 1/4-20 flange head screws in place. Leave one (1) crossbar aside for mounting the fairing.
Always make sure to assemble and secure Flatline Van Co products properly before attaching them to your vehicle to avoid any automobile accidents that could result in serious bodily injury or death to you or others involved. It is recommended to use a professional installer or other qualified persons for installation you have no mechanical experience and are not thoroughly familiar with the installation procedures.
All Flatline Van Co products must be properly assembled and secured before attaching to your vehicle. Improper attachment could result in an automobile accident, and could cause serious bodily injury or death to you or to others involved. You are responsible for assembling and securing flatline van co products to your vehicle, checking the mounting points and attachments prior to use, and regularly inspecting the products for wear and or damage. We always recommend you use a professional to install any aftermarket accessories to your vehicle. If you have no mechanical experience and are not thoroughly familiar with the installation procedures, you must have the product installed by a professional installer or other qualified persons. The responsibility is yours and must be taken seriously for everyone’s safety.
THANK YOU!
ARE YOU EXCITED ABOUT YOUR NEW LOW PRO ROOF RACK? HERE ARE A FEW THINGS TO
DO BEFORE BEGINNING THE INSTALLATION PROCESS–
- PLEASE INSPECT THE PRODUCT TO ENSURE THERE WAS NO DAMAGE INCURRED DURING SHIPPING.
- IF THERE IS DAMAGE TO REPORT, PLEASE CONTACT OUR CUSTOMER SERVICE DEPARTMENT AS SOON AS POSSIBLE.
- NEXT, USING THE “PACKAGE CONTENTS” PAGE, CHECK INVENTORY AND FAMILIARIZE YOURSELF WITH THE PARTS AND HARDWARE.
- GATHER ALL TOOLS REQUIRED FOR INSTALL.
- 5/32 HEX KEY ALLEN WRENCH
- 7/16 WRENCH OR SOCKET
- 13MM WRENCH OR SOCKET
TOOLS
PACKAGE CONTENTS
HARDWARE PACK
LET’S GET STARTED!
-
FIRST STEP IS TO ATTACH THE LANDING PADS TO THE TOP OF YOUR VAN USING THE SUPPLIED M8 HARDWARE AND SEALING WASHERS.
NOTE- DUE TO FACTORY INCONSISTENCIES YOU MAY NEED TO GRIND CLEARANCE ON THE HOLES OF YOUR VAN TO GAIN ACCESS TO THE THREADED HOLES. SEE FIGURE 1 TO RIGHT. -
AFTER TIGHTENING DOWN THE M8 BOLTS, IT IS OPTION TO USE A SEALANT AND RUN A BEAD ALL THE WAY AROUND THE LANDING PAD WHERE IT SEATS TO THE VAN. THE NEOPRENE GASKET SEALS THE LANDING PAD TO THE VAN BODY, BUT WE DO THIS ON OUR BUILDS JUST TO BE SAFE.
SEE FIGURE 2 (SAFARI BRACKET SHOWN)
-
NOW YOU CAN START ATTACHING THE SIDE RAILS USING THE 1/4-20 CARRIAGE BOLTS, 1/4 FLAT WASHERS, AND 1/4-20 NYLOCKS AS SHOWN IN FIGURE 3. MAKE SURE TO LEAVE THEM A LITTLE LOOSE TO ALLOW FOR MOVEMENT WHEN ATTACHING THE CROSSBARS
NOTE- YOU
WILL COME BACK TO TIGHTEN ALL BOLTS LATER. -
ONCE YOU’VE GOT ALL THE SIDE RAILS UP, FASTEN THE RAIL CONNECTING BRACKETS TO THE SIDE RAILS USING THE 1/4-20 FLANGE HEAD BOLTS, 1/4 FLAT WASHERS, AND 1/4-20 NYLOCKS (SEE FIGURE 4)
NOTE-
ALIGN THE SIDE RAILS AND BUTT THEM TIGHT TO EACH OTHER AS YOU TIGHTEN DOWN THE
CONNECTING BRACKET BOLTS. -
PLACE YOUR CROSSBARS IN DESIRED LOCATION, LOOSELY BOLTING THE 1/4-20 FLANGE HEAD SCREWS IN PLACE. NOTE- LEAVE ONE (1) CROSSBAR ASIDE FOR MOUNTING THE FAIRING WHEN PLACING CROSSBARS; KEEP IN MIND THE LAYOUT OF YOUR ROOF TOP ARRAY (SOLAR PANELS, FANS, TENTS, ETC.) YOU CAN MOUNT CROSSBARS IN THE SET PAIR OF HOLES (SEE FIGURE 5), OR YOU CAN PLACE THEM IN THE SLOTS WHICH PROVIDES YOU MORE FREEDOM OF LAYOUT.
-
AFTER PLACING YOUR CROSSBARS, GO BACK DOWN AND GRAB THE CROSS BAR YOU SET ASIDE TO BEGIN PUTTING TOGETHER THE FAIRING ASSEMBLY. YOU WANT TO START WITH THE THREE (3) FAIRING BRACKETS SHOWN BELOW, AND BOLT THEM TIGHT TO THE CROSSBAR IN THE LOCATIONS SHOWN IN FIGURE 7 USING THE 1/4-20 BUTTON HEAD SCREWS, 1/4 SPLIT LOCK WASHERS, AND T-NUT INSERTS AS SHOWN IN FIGURE 6
PRO TIP- IT IS EASIEST TO BARELY GET THE T-NUT INSERTS THREADED ON TO THE BOLT AND THEN SLIDE THE BRACKETS ONTO THE CROSSBAR FROM ONE END TO THE APPROPRIATE POSITION.
-
NEXT, GRAB THE FAIRING (PLASTIC) AND THE FAIRING GASKET, AND BEGIN INSTALLING THE GASKET BY PRESSING IT ONTO THE LOWER EDGE OF THE FAIRING WITH THE BULB SIDE OF THE GASKET TO THE INSIDE (SHINY SIDE) OF THE PLASTIC. SEE FIGURE 8 & 9 BELOW.
ONCE YOU HAVE THE GASKET INSTALLED, GRAB THE FAIRING ASSEMBLY YOU PUT TOGETHER
IN STEP 3, THE PLASTIC FAIRING, AND THE PASSENGER AND DRIVER SIDE RAIL FAIRING
BRACKETS AND BEGIN BOLTING THEM TOGETHER AS SHOWN IN FIGURE 10 UTILIZING A
1/4-20 FLANGE HEAD SCREW, 1/4 FLAT WASHER, AND 1/4 NYLOCK FOR EACH MOUNTING
HOLE. THE WASHER GOES UNDERNEATH THE NYLOCK NUT. DO NOT OVER-TIGHTEN THESE
CONNECTIONS; SNUG IS PLENTY! THE MOUNTING HOLES ARE ALL SLOTTED FOR SMALL
ADJUSTMENTS THAT MAY NEED TO BE MADE WHEN ATTACHING THE FAIRING ASSEMBLY TO
THE ROOF RACK.
FIGURE 11 TO THE RIGHT SHOWS THE FAIRING ASSEMBLY COMPLETE; WITH IT IN HAND,
CONTINUE TO NEXT STEP.
- this NEXT STEP IS EASIER WITH THE HELP OF A SECOND PERSON. YOU NEED TO SLIDE THE FAIRING ASSEMBLY INTO THE FRONT OF THE RACK AS SHOWN IN FIGURE 13. ONCE IN PLACE, THREAD TWO (2) 1/4-20 FLANGE HEAD SCREW INTS O THE CROSSBAR ON EITHER SIDE. THEN GRAB TWO (2) EACH 1/4-20 FLANGE HEAD SCREW, 1/4 FLAT WASHER, AND 1/4 NYLOCK AND BOLT THE RAIL FAIRING BRACKETS TO THE SIDE RAILS. FIGURE 12 TO THE RIGHT SHOWS THE INSIDE DETAIL. THE BRACKETS ARE SLOTTED FOR ADJUSTMENT.
NOTE- THE BOLTS JOINING THE RAIL FAIRING BRACKETS TO THE RAIL SHOULD BE
TIGHTENED DOWN, BUT REMEMBER THAT ONCE
YOU ADJUST THE FAIRING INTO POSITION; THE BOLTS SHOULD ONLY BE SNUGGED.
- TIGHTEN ALL CROSSBAR BOLTS USING THE 5/32 ALLEN KEY (SEE FIGURE 14)
NOTE- DO NOT OVERTIGHTEN! IF YOU ARE CONCERNED ABOUT THE BOLTS BACKING OUT, YOU CAN PUT A DAB OF BLUE LOCTITE ON THE BOLTS BEFORE TIGHTENING DOWN COMPLETELY.
- NOW TIGHTEN SIDE RAILS DOWN TO THE LANDING PADS. READY TO HIT THE ROAD!
- IF INSTALLING A FIAMMA F45S OR SIMILAR AWNING; WE HAVE CONVENIENTLY PLACED MOUNTING HOLES AS SHOWN BELOW FOR YOU TO BOLT YOUR SUPPORT BRACKETS TO; MAKING INSTALLATION A BREEZE!
GET OUT AND EXPLORE!
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CUSTOMER SUPPORT
If you are having any issues with your product, please reach out, and we will
make it right. FVC is a company of van and outdoor enthusiasts that design and
use our own products, so we want you to be as stoked on your new parts as we
are!
FLATLINE VAN CO • SUPPORT@FLATLINEVANCO.COM • 888-667-5576
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