UPTOP 2001.3 Colorado Bravo Roof Rack Instruction Manual

Colorado/Canyon
Roof Rack-BRAVO
Instruction Manual

2001.3 Colorado Bravo Roof Rack

Effective 2023 we are making some changes to our products that might not be reflected in this guide. Major changes for 2023 include:

• Removal of lock washers from hardware kits in some cases.
• Switching to through-bolt assembly on Alpha roof racks instead of rivet nuts.
• Revised slot array in grooveTEK on Alpha/Bravo roof racks.

Thank you for selecting upTOP™ as the choice for your vehicle. The roof rack designed for your platform requires competency with basic handle tools and assembly procedures. If you are not comfortable or you feel it is above your pay grade you are encouraged to seek professional installation of this product.
WARNING
Installation of this product requires drilling holes in your vehicle. It is the responsibility of the installer to ensure vehicle components are not damaged during this process. Check and verify all locations for clearance prior to drilling. upTOP will not be held responsible for damage resulting from the installation of this product.

TOOLS REQUIRED

• 5/32 Allen wrench
• 3/16 Allen wrench
• 5mm Allen wrench
• 1/2” wrench
• 10mm wrench (2)
• Cordless Drill
• Hammer
• Masking Tape
• Silicone Sealant
• Marker
• VibraTITE VC-3 Thread locker (Included)

The weight capacity restrictions for your vehicle are:

• 175 pounds dynamic/moving
• 350 pounds stationary

Restrictions assume evenly distributed cargo. Failure to comply can result in damage or serious injury.
You will need adequate floor space to assemble your roof rack prior to installing it to your vehicle.
An area 80×80” is recommended for this assembly.
You are encouraged to inspect the contents of your package prior to completing assembly and installation. For any missing/damaged parts email pictures and descriptions to [email protected] with your order number as reference in the subject line. A specialist will assist you with the process for field repair or component replacement.
It is important to plan for any wiring that needs to be completed during the course of rack installation. Incorporate these steps into the steps in this guide at points that reduce additional disassembly of the rack while it is installed on the vehicle.

BRAVO Series Roof Rack-Assembly

What’s in the box:

*Options vary based on order preference. Additional hardware may be included with windscreen. See “Windscreen Lighting Guide” under instructions tab on website for detailed instructions regarding light bar mounting.

• You will assemble the rack on the ground and move to vehicle.
• Roof rack will be used as guide/template for drill position marking.
• Remove roof rack from vehicle for drilling and mounting hardware installation.

STEP 1 Feet to Rack

1305
These are your front feet. They are the same for the driver and passenger side. 1307
These are your rear feet. They are the same for the driver and passenger side.
Start with the front (1305) feet. We are showing you the driver side roof rack panel (2001.3) but the steps are the same for both driver and passenger (2001.4).
Grab the hardware bag that says “Foot to Rack-Front”. You will need a 3/16” Allen wrench and a 1/2” wrench or ratchet/socket combo. You are going to place those short aluminum spacers between the foot and the inside of the roof rack. This will give you the right alignment to your drip rails when you put the rack on the truck. Align the hardware to the hole and the slot highlighted in pink.
Your spacers will be silver, not yellow as pictured. Some of our drawings require details like changing the color of parts to show contrast in three dimensional drawings. Why did I have to mention that? We’ve actually had that phone call.
Put the hardware together as shown above and tighten them up. Just snug them. They need to be able to move (swivel) to adjust to the curve on the roof of your truck.
Go ahead and install the other 1305 the same way on the passenger side.
Once you’ve got them both installed you can move on to the back feet.
Your rear feet are part number 1307. Like the front they are the same for both sides.
You’ll need the hardware bag labeled “Foot to Rack-Rear”. These feet use the same tools as before but the bolts are a bit shorter and there are no spacers required between the feet and the inner rack side.
Again we are showing you the driver side (2001.3) but the same steps are used for the passenger side (2001.4).Line up your feet and install the hardware. Use the 3/16” Allen wrench and 1/2” wrench to tighten the feet.
You can fully tighten the hardware on the rear feet at this time. There is no angle adjustment required to line up on the roof at the rear of the vehicle.
Install the last 1307 rear foot onto the passenger side (2001.4). Once you’ve got that under control we can put the cross bars in.

STEP 2 Cross bars

All of the cross bars shipped with your rack are the same size and can be used in any of the available mounting locations in the rack body.
Some of the cross bars are adjustable and some of them are not. We will go over the details in this section.
To start get the bag of hardware that says “Load Bars” and a 5/32” Allen wrench. All of the bolts for attaching cross bars are the same. Start with the two positions located above in the Pink circles. These two positions are fixed (non-adjustable) and will make sure that your roof rack remains square (even from side to side).
NOTE
Depending on when you purchase your rack you may or may not have lock washers in your hardware bag. We are phasing out the use of lock washers.

• If your kit includes lock washers, use them.
• If your kit does not include lock washers you should apply thread locker to the threads of each bolt.

Use a 5/32” Allen wrench to tighten the hardware on these two (2) cross bars. We are showing you the driver side.
Align the passenger side and do the same thing and then you will be ready to put in the remaining cross bars.
You’ve got some options for the rest of the cross bars. At the front of your rack you can install the load bar horizontally (as pictured) in the slot. You can also rotate the load bar vertically and use the slot for the upper bolt and any of the three holes shown in Pink for the lower bolt. The advantage of the vertical orientation is that the cross bar is more rigid turned on its side and we provide the two configurations to allow for options when mounting optional light bars into the front of your rack.
Once you’ve made your decision install the front load bar. Connect both sides of the rack using your 5/32” Allen wrench. You can always change the orientation later as needed.
WIND NOISE
We try really hard to make these racks as silent as possible. It is important that if you ordered a roof rack with a specific light bar option that the light bar be installed for proper operation of the windscreen in reducing noise. Wind screens designed to have light bars installed without lights can be noisy.
In all instances you will want to keep the front load bar pushed as far forward in the roof rack as possible while allowing room for optional lighting. When roof racks are fully loaded with gear the front load bar can be placed anywhere in its available slot.
If you encounter wind noise or vibration slight adjustments to the position of the front land bar can usually tune that out without the need for technical support.
The rear cross bar can also be installed vertically or horizontally. The orientation of this cross bar is strictly user preference and can be changed at any time.
Make the decision and install the rear cross bar. Use the 5/32” Allen wrench to tighten into place. Be sure to connect both sides of the roof rack.The remaining two cross bars are adjustable allowing you to shift them forward/backward in the slot. You can mount them at any position within the slot, just make sure they are even with each other on both sides of the rack.The last two load bars are for the center of the roof rack and you will install them into the slots shown above in Pink.
You can put them at any location in the slot just be sure they are even on both sides of the rack. If they are uneven they can push the sides of the rack out of place and cause alignment issues on the roof of the vehicle.
These can be adjusted at any time.
Once you have all six load bars installed you can move on to installing your wind screen.

STEP 3 Wind Screen

Depending on your order preferences your wind screen could look very different than the one used in this guide. For information on how to mount light bars into all of available options please check out our “Wind Screen Lighting Guide” located under the instructions tab on our website.
In some applications we will advise to install light bars before placing roof rack on vehicle. For some applications that use heavier or more complicated lighting options we recommend installing the lighting once the roof rack is securely mounted on the vehicle.
Specifics are in the guide.
All variants of windscreen will attach to your roof rack in the same manner.
Locate and rip open the bag of hardware labeled “Wind Screen” (depending on who printed them they may say “Fairing”…a word that I detest.) Same thing.
You will need the 3/16” Allen wrench and 1/2” wrench you used for the “Feet to Rack”. Align the bend flanges of your wind screen to the holes shown in Pink at the front of your rack.
NOTE
Your wind screen will not be see-through. The illustration is provided for clarity on where the hardware should be placed. Disclaimer required for the seventh place trophy world we all now live in.
Connect both roof rack sides to the wind screen and tighten with the 3/16” Allen wrench and 1/2” wrench.
Once you have the wind screen installed you’re ready to get this puppy on your truck.

STEP 4 Vehicle Mounting

Before the rack can be installed to the vehicle you are going to have to drill and install the mounting hardware provided with your hardware kit. Without the hardware you have no place to attach your roof rack. If at any time you do not feel comfortable with this process please seek professional installation.
WARNING
Damage to vehicle or serious injury can result from improper installation. This process requires the use of power tools and drilling into vehicle surfaces. The metal in the drip rails is quite thick and this process can be difficult. Failure to verify clearance for fasteners can result in damage to vehicle safety systems. It is the responsibility of the installer to ensure proper installation of the included fasteners. By installing this roof rack to your vehicle you are assuming all responsibility. DO NOT under any circumstances drill into the side curtain airbags or associated wiring. Failure to use the supplied stop collar on the provided drill bit or improper use of stop collar can result in damage to vehicle interior.
Vehicle Preparation:

• You will need to remove the black drip rail trim on both sides of the roof before marking and drilling the vehicle. The included fasteners CANNOT be installed on top of the drip rail trim.
• The drip rail trim is held in place by plastic clips located along the length of the drip rail trim.
• The drip rail trim is a thin metal material and will easily deform during removal.
• You do not have to re-use the drip rail trim for roof rack installation. Can be modified/cut to go around mounting foot areas if so desired.
• Clean the drip rail areas to promote better adhesion of sealant (not included).
• When we install roof racks at our facility we always apply masking tape to the outer surfaces of the vehicle in areas where the roof rack might come into contact during installation to prevent surface scratches from moving the rack around before it is secured. Just about any masking tape will do the trick and can be found at most hardware stores. We use 3M 233 which is green and stupid expensive but it is easily to remove.

NOTE
The assembled roof rack (with no additional lighting/wiring installed) weighs around 60 pounds. It is incredibly awkward to try and put the roof rack on the vehicle by yourself. We recommend getting a friend to help with the steps that follow.
With the factory drip rails removed:

• Lift the roof rack up and onto the vehicle and gently sit it down.
• At this time the feet will be in contact with vehicle surfaces so DO NOT scoot the rack around.
• Align the roof rack on the vehicle so that the slots in your mounting feet line up over the drip rails of the vehicle. Pick the rack up and adjust as needed and gently sit it back in place.

NOTES ON LOCATION
No two vehicles are produced exactly the same. There are slight variations that prohibit us from giving you visual indicators related to factory spot welds, seams, or retainer clips on vehicles that are not equipped with a factory roof rack.
In order to locate the roof rack properly on the vehicle observe the following:

• Can you clearly verify that the slots in your mounting feet are centered over the drip rails? If not adjust until they are.
• Visually look at the roof rack and make sure that it is sitting on the vehicle in position centered front to back as well as left to right (driver to passenger side). Adjust as needed.
• With the rack centered on the roof use a marker to reach through the slots in the feet and carefully mark the locations to drill into the drip rails.
• Remove the roof rack from the vehicle and proceed to drilling.

DRILLING

Your hardware kit includes the appropriate drill bit size for the provided plusNUT fasteners. It is strongly recommended that you start with smaller drill bits to make a pilot hole. Smaller drill bits remove less material and work faster. Trying to drill the large hole from the start will take much longer and the heat can dull the bit before all of the holes are drilled. If we are doing this we would use:

• 1/8” Drill bit for pilot hole. Center yourself in the areas you marked and slowly drill the pilot holes. Do not use a high speed gear for this process. If drill bits aren’t spitting chips they aren’t cutting correctly. Going fast generates heat. Heat dulls drill bits. If you do not have a drill stop for the smaller drill bit use extreme caution not to go too far into vehicle interior.
• Once you have the 1/8” holes drilled proceed to 1/4” Drill bit. Again slowly enlarge the holes with the 1/4” drill bit. If you do not have a drill stop for the smaller drill bit use extreme caution not to go too far into interior of vehicle.
• With all of the holes enlarged to 1/4” you can proceed to finish enlarging the holes with the provided drill bit and stop collar.

STOP COLLAR SETTING

It is important to set the stop collar to a depth that is close to the thickness of the material in your drill rails. By drilling the smaller pilot holes you should be able to visually inspect the thickness of the material and set your stop collar accordingly. You want to just break the surface of the material in your drip rail. Adjust as needed.

plusNUT INSTALLATION

The hardware we provide is designed to add very strong threaded anchors in places that you normally wouldn’t be able to mount things. These are easy to install with the provided kit and do not require any specialized tooling to complete the installation.
You will install one (1) plusNUT into each of the holes you drilled. There should be eight (8) holes. Assemble the included installation kit as indicated above. You’ll need a small wrench (smaller than your washers, we use a 10mm), and an additional 10mm wrench or ratchet/socket to install the plusNUT
You will repeat this step each time until all of the plusNUTS are installed.
Use a hammer to tamp the assembly down into the drilled hole until the lip of the plusNUT is flush with the drip rail. Operate the tools as shown below. As you perform this operation the plusNUT will begin to form inside the roof of the vehicle pulling the threads up towards you and properly seating the fastener.
Continue to operate the wrenches until they get difficult to turn. You want to fully seat the plusNUTS so that they grip properly. They form an “X” under the roof and provide a tremendous amount of grip that allows your rack to hold all the adventure gear you need. Take your time here and do this correctly. When properly seated the plusNUTS will no longer rotate at all and will be stationary.
DO NOT over tighten the plusNUTS and DO NOT use power tools for this process. You can easily pull or deform the threads and cause yourself a big headache when you try to install the roof rack hardware.
Once seated use “wrench B” to remove the bolt. Retain the bolt and both washers for continued use.
Repeat the process until all eight holes have the plusNUTS installed.

RACK TO ROOF

Relax. The hard part is over. You’re really close to getting the rack on your roof for good.
For this next part you’re going to need:

• Silicone sealant. Just about any silicone sealant will get the job done and you can get it at most hardware stores or from Amazon. It can be clear, white, black, or whatever. You won’t see it after the rack is installed. We use RTVThis stuff can be incredibly messy. Take care not to get it on the exterior of the vehicle during application. If you are using a gun to dispense be sure to release the pressure prior to sitting the gun down. They tend to drool and it is a really good way to get silicone all over your vehicle and your clothes.
• Hardware. Grab the bags that say:
  • Rack to Roof-Front
  • Rack to Roof-Rear
• 5mm Allen wrench
• Friend

The Bolts and spacers are different lengths for front and rear so do not get them mixed up.
If you do…….the REAR feet get the shorter bolts and spacers. Before you lift the rack onto the truck again you’ve got to apply your sealant and place your spacers.
That beautiful Pink glob represents the sealant area you need to cover.

• Start inside the threads of each plusNUT and work your way out making a pool of sealant about the size of a nickel. (If you aren’t in the US I have no idea how big your coins are, sorry.) Should be a little bit bigger than the diameter of your spacer which is 3/4” (19mm ;))
• Place your spacers into the pool of sealant and give them a little spin to seat them.
• If you used masking tape now would be a good time to remove it.

THE SHORTER SPACERS GO AT THE REAR LOCATIONS. The longer ones go at the front. Each foot location gets two spacers. BEFORE you lift the rack onto the roof of the truck remove the load bar indicated above in Yellow.
With the load bar installed the foot hardware is difficult to install. You can put it back after the rack is secured to the vehicle.
When you have all eight spacers in place get that friend of yours and have them help you lift the roof rack back onto the vehicle.
Align the slots in the feet of your rack over the spacers and GENTLY sit the rack down into place.
The LONGER hardware goes at the FRONT of the rack.
NOTE
We are phasing out lock washers on all of our roof racks. If your kit shipped with lock washers it is okay to use them. If your kit did not ship with lock washers they are not required.
Use a 5mm Allen wrench to START the hardware in all four FRONT locations. DO NOT TIGHTEN YET. The SHORTER hardware goes at the REAR of the rack.
NOTE
We are phasing out lock washers on all of our roof racks. If your kit shipped with lock washers it is okay to use them. If your kit did not ship with lock washers they are not required.
Use a 5mm Allen wrench to START the hardware in all four REAR locations. DO NOT TIGHTEN YET.

FINAL STEPS

• Take a look at the rack on the vehicle. Shift it around until the rack is centered front to back and left to right.
• Once you are satisfied with the placement of the rack proceed to tighten all of the hardware with the 5mm Allen wrench.
• With all eight rack to roof bolts tightened you can fully tighten the “Foot to Rack” front hardware with the 3/16” Allen wrench and 1/2” wrench. Tightening the rack to roof hardware pulled the front foot to the correct angle for you.
• Reinstall the load bar that covers the rear rack to roof hardware.
• Check over all of your hardware and ensure that everything is tight.
• Complete any optional lighting or wiring that you might have.
• Step back and admire all of your hard work. You earned it.

Do not wash the vehicle for 48 hours allowing time for the sealant to fully cure. If you ever need to remove the rack for any reason you will need to re- apply your sealant prior to re-installation.
If you have any questions or need support on this product we are available via email or phone. We are easily contacted through our website.

upTOP finePRINT

• It is recommended to inspect the rack hardware at regular intervals to ensure fasteners are tight. If the rack ever needs to be removed and reinstalled you will need to repeat the silicone sealant steps before reinstallation of the rack to roof hardware.
• The powder coated finish on your rack uses a chemical compound to maintain UV stability for years to come. Wash the roof rack at regular intervals to keep the load bar channels, drip rails and mounting components free of dirt and debris. Foreign objects (mud) can dry and cause noise and vibration.
• If your color matched components are painted care for them in the same manner as you care for the exterior finish of your vehicle.
• Repair or replace worn parts with expediency. All hardware is available for purchase by calling our technical support line at 720.730.6381 Monday-Friday 8am to 4pm MDT or by email 24/7 364 (we don’t answer email on Christmas-get over it) [email protected]
• It is the responsibility of the end user to ensure all electrical connections are secured and fused properly for the circuit load they are carrying.
• upTOP Roof Rack dynamic (moving) weight capacity can often exceed the OEM vehicle manufacturers specification. In all cases the OEM specifications supersede the upTOP dynamic rated load capacity.
• DO NOT use the upTOP product in a manner inconsistent with its design intention. This will void your warranty.
• DO NOT modify or alter structural components of upTOP roof rack assemblies. This will void your warranty.
• Excessive speeds over rough terrain can exceed dynamic weight loads causing structural fatigue or failure of aluminum and steel components. Use your best judgement and common sense before committing to full send with an overloaded rack product.
• Component damage or failure due to negligence will result in voided warranty claims. Any failed component must be returned to upTOP with a properly submitted RMA request. Any product received without authorized RMA request will be returned to sender at their expense.
• Leave. No. Trace. Our planet is fragile. Some parts of it have been undisturbed for generations. Stay on trails and designated routes. DO NOT LITTER. Pack it in Pack it out. Basically be a decent human and protect our culture, wild lands and ecosystems.

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