SHERPA 2018-2023 JL Jeep Wrangler Roof Rack Instruction Manual

SHERPA 2018-2023 JL Jeep Wrangler Roof Rack

Product Information

The Starlight is a roof rack designed for vehicles. It has a maximum load capacity of 150 lbs, as recommended by the vehicle manufacturer. The rack includes various hardware components such as carriage bolts, hex bolts, flat washers, T-nuts, split washers, and
mounting bracket assemblies. The package also includes sideplates, extrusion crossbars, a wind fairing with edge trim, and installation instructions.

Product Usage Instructions

1. 1.  **Step 1: Hardware Checklist**

Before starting the installation, check the hardware included in the package. The exact counts may vary based on the options selected at checkout.

1. 1.  **Step 2: Fairing Assembly**

Required Components: 6x 1/4-20 x 1/2 socket button bolts, 6x 1/4 flat washers, 6x T-nuts

1. 1.       1. Drop 6 T-nuts into the slots on the crossbar and align them with the holes in the fairing.

   2. Secure the fairing to the crossbar using six 1/4-20 x 1/2 socket button bolts and washers.
2. Step 3: Mount Assembly 01

Required Components: 24x carriage bolts (1/4-20 x 1), 24x flat washers, 24x 1/4-20 hex nuts, 16x split washers

1. 1.       1. Ensure that the clamping mount assemblies are preassembled in the same configuration as pictured.

   2. If any hardware has fallen off during shipping, reassemble according to the diagrams.
   3. Leave the horizontal set of hardware loose for now. This hardware will secure the outer clamps to the mounting foot assembly.
   4. The vertical sets of hardware are not for attaching the outer clamps but act in tension to keep the roof rack on the vehicle.
2. Step 4: Mount Assembly 02

Required Components: 16x 1/4-20 x 7/16 hex bolts, 16x 1/4 flat washers, 16x 1/4 T-nuts

1. 1.       1. Secure the tops of the mounting brackets to the wide faces ofthe crossbars using the supplied T-nuts, hex bolts, and flat washers.

   2. Leave the hardware that attaches the mount to the crossbar loose for now.
2. Step 5: Roof Diagram

Refer to the provided roof diagram to understand the placementof mounts in relation to the vehicle. The rack includes front mounts (F), middle mounts (M), and rear mounts (R).

1. 1.  **Step 6: Mount Assembly 03**

With the mounting assemblies still loosely attached to the crossbars, place the edge-trimmed mounting foot into the rain gutter channel above the doors of the vehicle. The outer clamp should sit loosely over the outside of the rain gutter.

For a more detailed step-by-step walkthrough, you can refer to the comprehensive installation instruction video available on the Sherpa Equipment website or YouTube channel.

Sherpa Equipment website: https://sherpaequipmentco.com/instructions

YouTube: https://www.youtube.com/@sherpaec

HARDWARE CHECKLIST

BEFORE YOU BEGIN

Want a step-by-step walkthrough? Want to hear the sweet sound of Chase’s voice? There is a comprehensive installation instruction video available for this roof rack.
Sherpa Equipment website:
https://sherpaequipmentco.com/instructions
Youtube:
https://www.youtube.com/@sherpaec
NOTE:
The maximum load capacity of this roof rack is 150 lbs, per the vehicle manufacturer’s recommendation.

ASSEMBLY

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 crossbar and line them up with the holes in the fairing. Secure with six 1/4”-20 x 1/2” socket button bolts and washers.

MOUNT ASSEMBLY 01
Required Components:

• 24x Carriage bolt 1/4”-20 x 1”
• 24x Flat Washer
• 24x 1/4”-20 Hex Nut
• 16x Split Washer
• The clamping mount assemblies should come preassembled in the same configuration as pictured. If any hardware has fallen off during shipping, simply reassemble according to the diagrams.
• The horizontal set of hardware is the main hardware that will keep the outer clamps secured to the mounting foot assembly. Leave these loose for now.
• The vertical sets of hardware act in tension as a means of keeping the roof rack on the vehicle but are not specifically for keeping the outer clamp attached to the mounting brackets.

HORIZONTAL HARDWARE SET

VERTICAL HARDWARE SETS

MOUNT ASSEMBLY 02
Required Components:

• 16x 1/4”-20 x 7/16”
• 16x 1/4” Flat Washers
• 16x 1/4” T-nuts
• Secure the tops of the mounting brackets to the wide faces of the crossbars using the supplied T-nuts, 7/16” 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.

ROOF DIAGRAM

The image below can be used as a guide on where the mounts sit in relation to the vehicle, which ensures the best fitment and functionality of the rack.
Notice that the mounting brackets are not all the same. Your rack should include the following mounts:

• 2x Front Mount (F)
• 4x Middle Mounts (M)
• 2x Rear (R)
• The mounts will have their respective markings on the top flange.
• There will be six ‘short’ outer clamps for the front and middle mounts. The rear mounts will utilize the two taller clamps.

The measurements below are approximate. Final placement of the mounts will result from where the fairing and sideplates best fit on the vehicle.

MOUNT ASSEMBLY 03
With the mounting assemblies still loosely attached to the crossbars, place the edge-trimmed mounting foot into the rain gutter channel above the doors of the vehicle according to the diagram in the previous step. The outer clamp should sit loosely over the outside of the rain gutter.

MOUNT ASSEMBLY 04
Center each of the four crossbars on the roof by measuring the distance from the ends of the crossbar to the inside-edge of the mounting brackets on either side of the vehicle. Slide the crossbar side-to-side in relation to the mounts until all are centered. Tighten the 1/4”-20 x 9/16” hex bolts on the underside of the mounting feet to secure the crossbars to the feet.

SIDEPLATES
Required Components:

• 16x 1/4”-20 x 1” Socket Button
• 16x 1/4” Flat Washer
• Fasten the sideplates to the ends of the four mounting-foot crossbars using the supplied 1” socket buttons and flat washers in the designated mounting slots.
• Move the sideplate to the position where it best matches the curvature of the vehicle’s roof. Installation of the wind fairing, which is outlined later in the installation guide, is a good way to ensure that the rack is placed in the correct location on the vehicle.

MOUNT ASSEMBLY 05
Once the rack is in its final resting location, tighten down the hardware on the mounts. The following steps will ensure the brackets are properly installed and not overtightened. For more clarity, it may be helpful to watch the installation video available on Sherpa Equipment Co.’s website.

1. Get the horizontal set of hardware finger tight. The outer clamping component should sit flat against the inner mounting foot.

2. Begin tightening the vertical sets of hardware until the bottom flange of the outer clamping bracket is firmly mounted against the bottom surface of the rain gutter channel. Tighten the nuts to be finger-tight, then tighten the nut an additional 180° with a wrench. The split washer should begin to compress.
   Also note that when installed, the two flanges between the outer clamp and the inner mounting foot will not touch. This is by design.

3. Completely tighten the horizontal hardware. This can be torqued all the way and is less prone to being overtightened.

4. Double check the vertical hardware. Overtightening these can bend the brackets or crack the fiberglass roof. All components at this stage should be rigidly mounted.

WIND FAIRING

Required Components:

• 4x 1/4”-20 x 1” Socket button
• 4x 1/4” Flat Washers
• Position the wind fairing in line with the diagonal slot at the front of the rack. Align the top edge of the fairing with the top radius of the roof rack and secure it using four 1” socket buttons and washers. Note that the wind fairing is NOT intended to sit on the vehicle’s roof – a small gap of 1/8” – 1/4” is ideal.

CROSSBARS

Required Components:

• 16x 1/4”-20 x 1” Socket Buttons
• 16x 1/4” Flat Washers
• 4x 56” Crossbars
• Secure all of the remaining crossbars to the rack system using the 1” socket buttons and washers in the open slots in the sideplate. Position according to your load requirements.
• For light bar applications with the half-sized fairing, the bracket can be installed on the fairing crossbar, or on the front mount crossbar.

HALF RACK

Planning on taking the Freedom Tops off of your Jeep? The rear portion of the rack can be installed stand-alone to allow for plenty of storage and still have room in the cabin.
To remove the front half of the rack, simply loosen the three hex nuts down to the ends of the carriage bolt threads on each of the mounts. Lifting the front half is easiest with the assistance of another person.

EXPLORE.

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.

References

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