SHERPA THE BIG BEAR Instruction Manual
- June 3, 2024
- SHERPA
Table of Contents
THE BIG BEAR
INSTALL INSTRUCTIONS
HARDWARE CHECKLIST
Exact hardware color counts may vary based on the options selected at checkout.
BEFORE YOU BEGIN
This is considered an expert level install. IF you are not confident about the
drilling process we recommend seeking the help of a local install shop.
TOOLS REQUIRED: Drill, 3/16” Drill Bit, 3/16” Rivet Tool, 7/16” Wrench,
7/16” Socket, 5/32” Allen Key,
RECOMMENDED: Drill Bit Stopcollar (set at 1”)
USING TNUTS
| FLAT | CONTOURED |
|---|
IMPORTANT NOTES
RIVET ATTACHMENTS
There are two different types of rivet attachments in your hardware package.
It is important that the contoured attachments go on the front of the vehicle
and not the rear.
Double check that you have the right attachments before starting the riveting
process.
OEM EDGE TRIM
During the install, you will need to remove the black factory edge trim from
the roof gutter. We recommend reinstalling this after your rack is on.
PRE-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.
PRE-ASSEMBLY
Required Components:
8x 1/4”-20 x 9/16”
8x 1/4” Flat Washers
8x 1/4” Tnuts
Secure the top of the mounting brackets to the two main cross members.
Leave the hardware that attaches the mount to the crossbar loose. This will
make it easier when centering the bars later.
-
Required Components:
8x 1/4”-20 x 1”
8x 1/4” Flat Washers
Now secure the two main cross members with mounts to the side plates of the rack. Position the crossbars in the center of the short slots on the side plates. You should see one slot in the front, and one in the rear, just in front of the mountain. Align the small slots in the rack side with the ends of the main support cross members. Secure it using 8 bolts and washers. Leave the bolts loose enough to move the side plate to the position that matches the curve of the vehicle. Once the rack is positioned correctly, tighten down all of the hardware for the rack sides, mounting hardware, and roof rack bolts. -
Required Components:
4x 1/4”-20 x 1”
4x 1/4” Flat Washers
Position the wind fairing in line with the diagonal slot at the front of the rack. Align the bottom of the fairing with the tip of the roof rack and secure it using 4 bolts and washers. -
Required Components:
12x 1/4”-20 x 1”
12x 1/4” Flat Washers
Secure all of the remaining cross members to the rack system. Position according to your load requirements. Position the assembled rack on the roof of your vehicle. Place the rivet attachments under the mounting brackets. You will mark your positions in the next steps. This assembled rack will serve as your drilling template. We recommend loosening the bolts and adjusting the rack to best match the curve of the vehicle at this stage. Use a tape measure and center all of the bars on the vehicle. We recommend
measuring from the inside edge of the mount to the outside face of the crossbar.
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 3/16” Drill Bit
Recommended Tools:
1x Drill Bit Stop
With the rack on the truck mark the position for each rivet attachment using a piece of painter’s tape. USE 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 is important to make sure that the rack fits your vehicle correctly. Measure 3 times and check 4 times. We recommend removing your headliner to be sure that you do not damage anything beneath the roof of your vehicle. But, it can be done without doing so if you are EXTREMELY careful. We are not liable for any damage caused to your airbags.
Once you have your start points marked with the punch, drill a hole using a 3/16” drill bit. You can also start with a smaller pilot hole. We recommend using a drill bit stop set at a shallow setting. DO NOT allow the drill bit to plunge after the hole is drilled. The side curtain airbags are located in this section of the roof. There is a decent bit of room but you want to prevent going any farther than you have to. It is important to use a 3/16” drill bit to ensure proper rivet fitment. Also, make sure to keep the drill bit as still as possible while drilling. AGAIN, DO NOT allow the drill bit to plunge after the hole is drilled.
Once the holes are drilled, you can place the rivet attachment in the gutter to test your holes. Before inserting the rivets for the next step, please place silicone in the hole of the -
Required Components:
8x 3/16” Rivets
Required Tools:
1x Rivet Install Tool
Once all of your holes have been drilled it is time to work on installing the rivet attachments the rack will bolt to. As mentioned before, place a small dab of silicone in the hole before inserting the rivets. The rivets should feel snug in the hole. They may require a light tap to get them to pop into place. The tolerances here should be tight. Once this is done you are ready to compress them.
Slide your rivet tool over the thin end of the rivet. Slide it as far down as you can and apply downward force before compressing the handle. Squeeze the handle a couple of times until you hear a loud popping sound.
The rivet will compress inside the roof and the top of the rivet should break off. Repeat this process again until all of the attachments are installed.
Required Components:
8x M8 Bolts
8x M8 Flat Washers
Place the rack back on the roof of the vehicle and make any small adjustments
required. Bolt the rack system into the tops of the rivet attachments.
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.