ZOMBIE RACKS POV Expandable Cargo Rack System Instruction Manual

EXPANDABLE CARGO RACK SYSTEM

COMPREHENSIVE INSTALLATION OVERVIEW

Congratulations on purchasing your new ZombieRacks expandable cargo rack system! ZombieRacks is dedicated to providing versatile and durable cargo solutions that can withstand the toughest conditions – perfect for your postapocalyptic adventures or just a weekend getaway.

We know there’s a lot to go through here, but our racks offer a unique alternative to the other cargo rack options available – Please follow the instructions carefully to ensure the proper installation and safe usage of your new ZombieRacks system.

This instruction manual will cover all aspects of our UNIVERSAL expandable cargo rack system – For vehicle specific systems, please follow those specified instructions as they may have some changes from the instruction steps showcased in this manual.

1. GENERAL SAFTEY INFORMATION

Installers should take care to read these instructions carefully and thoroughly – an incomplete or rushed installation could damage components or leave components loose and result in an accident for the end user or other motorists on the road / on the water. Please note the following bullet points before you begin your installation, and if you have any questions / comments / concerns, please reach out to us for help you start.

• Verify all the correct tools and installation supplies have been purchased and are ready before you begin. Verify all system components are present and, if possible, lay out entire rack in planned configuration to be sure of correct quantities and that all rack items are accounted for.

• Always wear protective gear (gloves, safety glasses) during installation – Disposable latex / nitrile mechanic gloves are preferred and makes handling all items easy during install.

• Always be cautious if working on a ladder or on a suspended platform, especially when maneuvering large rack sections or complete racks.

• When lifting the assembled rack body onto the vehicle, it is always recommended to have a helping hand or two – in larger assemblies, the rack can become heavy and difficult to move & maneuver alone.
  (Doesn’t matter how strong you are, a thrown out back or hurt shoulder is never worth it)

• Be cautious when attaching stainless flanged nuts to their respective bolts. 316 stainless hardware can be assembled incorrectly and cause thread galling, requiring the nut to be cut off from the bolt for removal.
  ZombieRacks the use of an anti-seize lubricant during assembly on all stainless components to reduce the chance of thread galling. To learn more about thread galling, read in depth at BOLTDEPOT.COM.

• Assemble entire cargo rack system with loose hardware, tighten and torque to spec only after the entire rack is positioned and aligned correctly.

• Measure, mark, and verify positions twice, drill once – don’t rush. Use care in handling ZombieRacks components near your planned installation surface. Cover with heavy duty painters’ tape, moving blankets, towels, or equivalent to avoid unwanted scratches or scuffs during assembly. TAKE YOUR TIME AND BE EXTRA CAUTIOUS WHEN MOUNTING!
  : ZombieRacks and its partners disclaim any responsibility for any damages, injuries, or losses incurred during the assembly, installation, or use of this product. Users proceed at their own risk. By using this product, the user agrees to assume all risks associated with its assembly and installation..

• ZombieRacks that customers re-torque the entire assembly in a window of time after a completed installation. If installing on a road vehicle, we recommend re-torquing after 50 miles of street driving or 5 miles of rough off-roading. If installing on a marine application, we recommend re-torquing after the first 30 minutes of use in rough conditions that would prompt excessive movement.

• ZombieRacks suggests a visual inspection for loose hardware or damaged components before each use
  : DO NOT UNDER ANY CIRCUMSTANCES USE A ZOMBIERACKS PRODUCT THAT SHOWS SIGNS THAT IT IS UNFIT FOR USE, EVER.

• If unsure about any part of the installation process, contact us or a professional installer for assistance. ZombieRacks strongly recommends a professional installation if you as an installer do not feel 100% confident in your ability to perform the installation from start to finish.

2. REQUIRED INSTALLATION TOOLS

TOOLS BELOW ARE REQUIRED ON EVERY RACK SYSTEM INSTALLATION AND SYSTEMS INSTALLING ON EXISTING TRACKS

| Allen / Hex Keys – 4mm, 5mm, and 6mm. We prefer a multi-tool like the unit pictured, but a ¼” drive ratchet with hex bit sockets works just as well.
: ZombieRacks does NOT suggest the use of a cordless impact for installations due to the potential for thread galling on 316 stainless hardware – cordless impacts or power tools in general use is up to the installer and they assume all damage liability.
| Box End Ratcheting Wrenches – 8mm,10mm, and 13mm. The 8mm wrench will be exclusively used for Air Dam assemblies only. The 10mm wrench will be mainly used at longitudinal connection points while the 13mm wrench will be used on most mount connections.
| Anti-Seize – We prefer LOCTITE or MOLYKOTE anti-seize (or equivalent). Use on ALL 316 stainless bolt thread ends to help prevent thread galling.
| IN-LB Torque Wrench – 10mm & 13mm sockets & 5mm Allen / hex socket.
: ZombieRacks does NOT suggest the use of a FT-LB torque wrench as it could cause installer to over-torque hardware leading to damaged components.
| Moving Blanket / Towels – A large moving blanket or multiple towels is recommended to be placed on the mounting surface to protect against scrapes or dings on install.
: ZombieRacks or its partners are not responsible for damage of any kind during assembly – Use caution whenever moving parts around finished surfaces.

TOOLS BELOW ARE REQUIRED ON SYSTEMS THAT ARE BEING HARD MOUNTED OR WHEN MOUNTING A NEW TRACK SYSTEM

| Painters Tape – Useful for both marking out locations of drill points and to provide some protection from scratching / drill shavings upon installation.
: ZombieRacks or its partners are not responsible for damage of any kind during installation, test tape in an inconspicuous area beforehand.
| Tape Measure – Use to measure out drill locations when installing RivNuts or Expansion Nuts or to mark locations for through-holes when installing on a surface with access below the mount.
| Cordless Drill – Use to drill mounting holes when installing RivNuts or Expansion Nuts or to drill through-holes when installing on a surface with access below the mount. Drill bits vary by size depending on application. See below table for ZombieRacks supplied metric applications.

M6 Steel RivNut

| Use 10mm or 3/8” drill bit
M6 Expansion Nut|

Use 12.7mm or 1/2” drill bit

M6 Bolt (For through-hole install)

|

Use 6mm or 1/4” drill bit

| RivNut Tool – Use to install RivNuts. Beware of inexpensive RivNut tools that include low grade steel adapters, as they have a tendency to snap. Check out our website for recommended installation tools.
| Permanent Marker – Use to mark drill locations when installing RivNuts or Expansion Nuts or to mark locations for drilling through-holes.
| Silicone RTV Sealant – Use to seal all openings made during installation. ZombieRacks recommends use on RivNuts, expansion nuts, and through-hole bolt installations regardless of perceived water-tightness. ALWAYS better to have extra sealing power than not enough.
: ZombieRacks or its partners are not responsible for damage of any kind during installation, always check for water leaks before use AFTER product cures.

3. MOUNTING OVERVIEW

Due to the universal nature of our cargo rack systems, we have come up with numerous ways to mount these systems to your vehicle. If unsure about which application is best for your install, reach out to our team and we will be happy to go over each option in greater detail and help narrow down the best option for you.

TRACK NUT MOUNTING

Track nut mounting allows you to install hinge mounts to an existing Yakima track system, however, track nuts may fit in other track systems such as Thule, A.R.E, Rhino Rack, etc. This is our preferred mounting style, allowing for the most mounting adjustability and the strongest mounting to your vehicle as the rack load is distributed through the entire track.

Our track nuts measure 3mm tall by 20mm wide by 30mm long.

EXPANSION / RIVNUT MOUNTING

Expansion nut or RivNut mounting allows you to install hinge mounts to any surface that does not have any items below the mount, but that are difficult / impossible to access from underneath. These provide a waterproof seal when used in conjunction with an RTV sealant.
: ZombieRacks or its partners are not responsible for damage of any kind during installation, always do your research before drilling to make sure side curtain airbags / electronics are clear from drill path. This may require removing trim or dropping the headliner to verify any obstructions.

THROUGH HOLE MOUNTING

Through hole mounting allows you to install hinge mounts to any surface that does not have any items below the mount line and are easy to access from underneath.
NOTE: Zombieracks does not provide hardware for through hole mounting as it is impossible to know the exact M6 or 1/4″ bolt length requirement required for your specific install.

RAIN GUTTER MOUNTING

Rain gutter mounting allows you to install rack assemblies to MOST rain gutters. There are a couple different mount heights and mount angles available for these to be used on a wide range of applications. Before purchasing, please check the notes sections of each mount style to see if there is a reference to your specific install.

VEHICLE SPECIFIC MOUNTING

Vehicle specific mounts are available for select models – These systems will have their own dedicated instructions you can find on the products web page for download. If your specific vehicle is not listed, please reach out to our team and we will help determine the best mounting style for your needs.

4. HINGE MOUNT BREAKDOWN

Our hinge mount is the foundation to our expandable cargo rack system, allowing unparallelled adjustability so you can mount your cargo rack to just about any surface. Below is a breakdown on the hinge mount components along with required hardware per mount. Note that the below example showcases its use with track nuts – Expansion / RivNuts would replace these track nuts on installs using those other mounting styles.

ITEM

| DESCRIPTION| QTY| TORQUE SPEC
---|---|---|---

1

| Hinge Upper Mount|

1

| –| –

2

| Hinge Lower Mount|

1

| –| –

3

| Standard Mounting Plate|

1

| –| –

4

| M6 x 1.00 x 110mm 316 Stainless Socket Cap Bolt|

1

| 50 in./Lbs| 5.7 NM

5

| M6 Black Nylon Isolating Washers|

4

| –| –

6

| M6 316 Stainless Washer|

3

| –| –

7

| M6 316 Stainless Flanged Locknut|

1

| 50 in./Lbs| 5.7 NM

8

| M6 x 1.00 x 12mm 316 Stainless Socket Cap Bolt
(Only used with ZombieRacks track nuts – Expansion / RivNut will use a different length bolt, typically 20 or 25mm depending on application)|

2

| 50 in./Lbs| 5.7 NM

9

| M8 x 1.25 x 25mm 316 Stainless Socket Cap Bolt|

2

| 100 in./Lbs| 11.3 NM

10

| M8 316 Stainless Washer|

4

| –| –

11

| M8 316 Stainless Flanged Locknut|

2

| 100 in./Lbs| 11.3 NM

12

| ZombieRacks Track Nut
(Only used when installing on existing track system – Expansion / RivNut installs will include either (2) expansion nuts or (2) RivNuts per mount.)|

2

| –|

–

These hinge mounts are designed to be installed in 3 possible longitudinal positions (e.g from front to back on the rack assembly) – centered position, offset left (allowing a 30mm adjustment to the left) and offset right (allowing a 30mm adjustment to the right). These minute adjustments make all the difference in ZombieRacks ability to place the mount in exactly the right spot for your universal application. Latitude adjustments (e.g. from center of rack assembly to outside of rack, or side to side) can be made by sliding the mount and its hardware. Hinge mounts have a 11.5″ (29cm) latitude adjustment, although we recommend keeping as much of the standard plate in contact with the rack base as possible for the strongest configuration.

ITEM

| DESCRIPTION| QTY| TORQUE SPEC
---|---|---|---

1

| M8 x 1.25 x 25mm 316 Stainless Socket Cap Bolt|

3

| 100 in./Lbs| 11.3 NM

2

| M8 316 Stainless Washer|

6

| –| –

3

| M8 316 Stainless Flanged Locknut|

3

| 100 in./Lbs| 11.3 NM
FIGURE|

DESCRIPTION

A

| STANDARD POSITION – The centered position where the mount sits under the mounting plate

B

| OFFSET LEFT POSITION – Position is shifted 30mm to the left of the standard position

C

| OFFSET RIGHT POSITION – Position is shifted 30mm to the right of the standard position

D

| LATITUDE ADJUSTMENT – An 11.5” (29cm) range of adjustment is available for the hinge mount positions

5. RACK CONNECTION OVERVIEW

5.1 Length (Longitudinal) Connections: Individual assemblies are installed together using CONNECTOR SLUGS. These are a ¾” billet aluminum slug with two smooth holes for a bolt to pass through and come in a grey anodized finish.

ITEM

| DESCRIPTION| QTY| TORQUE SPEC
---|---|---|---

1

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

2

| M6 316 Stainless Washer|

4

| –| –

3

| Anodized Black Saddle Washer|

4

| –| –

4

| Connector Slug (Smooth Holes & Grey Anodized Finish)|

1

| –| –

5

| M6 316 Stainless Flanged Locknut|

2

| 50 in./Lbs| 5.7 NM
FIGURE|

DESCRIPTION

A

| Isometric Rack View – Connector slugs are highlighted to showcase longitudinal position between rack assemblies – Wasteland and HDR assemblies will use 1 connector per side, while DTR (Pictured) uses 2 connectors per side.

B

| Connector Assembly Breakdown – This is the hardware used on every connector slug, regardless of use with or without rail mounts or accessory mounts.

C

| Top Rack View – Showcasing the connector slugs use in lengthening the overall rack system by connecting intermediate assemblies (centered) to end assemblies.

5.2 Width (Cross) Connections: Cross sections are installed together using THREADED SLUGS. These are a ¾” billet aluminum slug with two M6 x 1.00mm threaded holes and come in a black anodized finish.

ITEM

| DESCRIPTION| QTY| TORQUE SPEC
---|---|---|---

1

| M6 x 1.00 x 25mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

2

| M6 316 Stainless Washer|

2

| –| –

3

| Anodized Black Saddle Washer|

2

| –| –

4

| Threaded Slug (M6 x 1.00mm Threaded Holes & Black Anodized Finish)|

1

| –| –
FIGURE|

DESCRIPTION

A

| Isometric Rack View – Threaded slugs are highlighted to showcase latitude position between rack assemblies

B

| Cross Bar Connector Assembly Breakdown – This is the hardware used on every crossbar connection

C

| Top Rack View – Showcasing the threaded slugs use in connecting the system together at the latitude points

NOTE: Connector Slugs and Threaded Slugs cannot be interchanged, which is why they come in two distinct colors – Take note when installing to position the correct slug in place before assembly.

5.3 Rack Width Overview: ZombieRacks offers (5) standard width crossbars for our rack systems. These cross bars relate to the OVERALL width of the rack (e.g. A 36″ WOA [Width Overall] crossbar would configure the rack to be 36″ wide from outside of tube to outside of tube.) Below is a breakdown of configuration widths through the available cross bars showcased on intermediate assemblies, although the same principles apply to flat end, radius end and short end assemblies as they all use these same crossbars and crossbar connectors.

ITEM

| DESCRIPTION
---|---

1

| 36” (91.44cm) WOA Crossbar [Note: ACTUAL Crossbar Length is 12” (30.48cm)]

2

| 42” (106.68cm) WOA Crossbar [Note: ACTUAL Crossbar Length is 18” (45.72cm)]

3

| 48” (121.92cm) WOA Crossbar [Note: ACTUAL Crossbar Length is 24” (60.96cm)]

4

| 54” (137.16cm) WOA Crossbar [Note: ACTUAL Crossbar Length is 30” (76.20cm)]

5

| 60” (152.40cm) WOA Crossbar [Note: ACTUAL Crossbar Length is 36” (91.44cm)]

FIGURE

| DESCRIPTION

A

| Cross Bar Cutaway – The two crossbars in this assembly are transparent to showcase the threaded slug connection points on each intermediate section where they join the crossbars.

B

| 36” (91.44cm) WOA Isometric Rack View – From outside edge of tube to outside edge of tube is 36.00”, with the addition of the connector hardware (Socket cap bolt, washer & saddle washer) on each side the ultimate WOA is 37” (93.98cm)

C

| 42” (106.68cm) WOA Isometric Rack View – From outside edge of tube to outside edge of tube is 42.00”, with the addition of the connector hardware (Socket cap bolt, washer & saddle washer) on each side the ultimate WOA is 43” (109.22cm)

D

| 48” (121.92cm) WOA Isometric Rack View – From outside edge of tube to outside edge of tube is 48.00”, with the addition of the connector hardware (Socket cap bolt, washer & saddle washer) on each side the ultimate WOA is 49” (124.46cm)

E

| 54” (137.16cm) WOA Isometric Rack View – From outside edge of tube to outside edge of tube is 54.00”, with the addition of the connector hardware (Socket cap bolt, washer & saddle washer) on each side the ultimate WOA is 55” (139.70cm)

F

| 60” (152.40cm) WOA Isometric Rack View – From outside edge of tube to outside edge of tube is 60.00”, with the addition of the connector hardware (Socket cap bolt, washer & saddle washer) on each side the ultimate WOA is 61” (154.94)

NOTE: The option for ZombieRacks to create a custom rack width is available, however, these custom crossbars will be billed as a non-refundable order with pricing based on the total number of crossbars needed for your rack assembly. Please contact us or your preferred ZombieRacks dealer for more information and pricing for your specific custom install.

6. Assembly Instructions

6.1.1 Intermediate Wasteland Assembly

FIGURE

| DESCRIPTION
---|---

A

| WASTELAND INTERMEDIATE ASSEMBLY – EXPLODED VIEW

B

| WASTELAND INTERMEDIATE ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| WASTELAND INTERMEDIATE ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

|

36 WOA ASSEMBLY

| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY

C1

| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

|

36” (91.44cm)

| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| INTERMEDIATE [Not Side Specific Can Be Used On Both Driver And Passenger Sides]|

2

| –| –

2

| Connector Slug|

2

| –| –

3

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt |

4

| 50 in./Lbs| 5.7 NM

4

| M6 316 Stainless Washer|

8

| –| –

5

| Anodized Black Saddle Washer|

8

| –| –

6

| M6 316 Stainless Flanged Locknut|

4

| 50 in./Lbs| 5.7 NM

7

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

4

| –| –

8

| Cross Bars (All WOA variants)|

2

| –|

–

6.1.2 Intermediate Hybrid Death Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| HYBRID DEATH RAIL INTERMEDIATE ASSEMBLY – EXPLODED VIEW

B

| HYBRID DEATH RAIL INTERMEDIATE ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| HYBRID DEATH RAIL INTERMEDIATE ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33.70” (85.59cm)| 39.70” (100.83cm)| 45.70” (116.07cm)| 51.70” (131.38cm)|

57.70” (146.55cm)

ITEM

| DESCRIPTION| QTY| TORQUE SPEC

1

| INTERMEDIATE [Not Side Specific Can Be Used On Both Driver And Passenger Sides]|

2

| –| –

2

| Connector Slug|

2

| –| –

3

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt |

4

| 50 in./Lbs| 5.7 NM

4

| M6 316 Stainless Washer|

16

| –| –

5

| Anodized Black Saddle Washer|

8

| –| –

6

| M6 316 Stainless Flanged Locknut|

8

| 50 in./Lbs| 5.7 NM

7

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

4

| –| –

8

| Cross Bars (All WOA variants)|

2

| –| –

9

| Hybrid Death Rail Support|

4

| –| –

10

| M6 x 1.00 x 25mm 316 Stainless Socket Cap Bolt|

4

| 50 in./Lbs| 5.7 NM

11

| Intermediate Hybrid Death Rail|

2

| –|

–

6.1.3 Intermediate Double Tap Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| DOUBLE TAP RAIL INTERMEDIATE ASSEMBLY – EXPLODED VIEW

B

| DOUBLE TAP RAIL INTERMEDIATE ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| DOUBLE TAP RAIL INTERMEDIATE ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33” (83.82cm)| 39” (99.06cm)| 45” (114.30cm)| 51” (129.54cm)|

57” (14cm)

ITEM

| DESCRIPTION| QTY| TORQUE SPEC

1

| INTERMEDIATE [Not Side Specific Can Be Used On Both Driver And Passenger Sides]|

2

| –| –

2

| Connector Slug|

2

| –| –

3

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt |

8

| 50 in./Lbs| 5.7 NM

4

| M6 316 Stainless Washer|

16

| –| –

5

| Anodized Black Saddle Washer|

16

| –| –

6

| M6 316 Stainless Flanged Locknut|

8

| 50 in./Lbs| 5.7 NM

7

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

4

| –| –

8

| Cross Bars (All WOA variants)|

2

| –| –

9

| Double Tap Rail Support|

4

| –| –

10

| Intermediate Run Tube|

2

| –|

–

6.2.1 Radius End Wasteland Assembly

FIGURE

| DESCRIPTION
---|---

A

| RADIUS WASTELAND ASSEMBLY – EXPLODED VIEW

B

| RADIUS WASTELAND ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| RADIUS WASTELAND ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| RADIUS END – DRIVERS SIDE|

1

| –| –

2

| RADIUS END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

6

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

4

| –| –

6

| Anodized Black Saddle Washer|

4

| –| –

7

| M6 316 Stainless Flanged Locknut|

2

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

3

| –|

–

6.2.2 Radius End Hybrid Death Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| RADIUS HYBRID DEATH RAIL ASSEMBLY – EXPLODED VIEW

B

| RADIUS HDR ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| RADIUS HDR ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

D

| RADIUS HDR ASSEMBLY – RADIUS HDR SUPPORT – RK (HIGHLIGHTED IN GREEN) CLOSEUP DRIVERS SIDE VIEW

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33.70” (85.59cm)| 39.70” (100.83cm)| 45.70” (116.07cm)| 51.70” (131.38cm)|

57.70” (146.55cm)

C4

| 33.08 (84.02cm)| 39.08 (99.26cm)| 45.08 (114.50cm)| 51.08 (129.74cm)| 57.08 (144.98cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| RADIUS END – DRIVERS SIDE|

1

| –| –

2

| RADIUS END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

6

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

12

| –| –

6

| Anodized Black Saddle Washer|

4

| –| –

7

| M6 316 Stainless Flanged Locknut|

6

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

3

| –| –

9

| Radius Hybrid Death Rail|

2

| –| –

10

| Radius Hybrid Death Rail Support – RK|

1

| –| –

11

| Radius Hybrid Death Rail Support – LK|

1

| –| –

12

| M6 x 1.00 x 25mm 316 Stainless Socket Cap Bolt|

4

| 50 in./Lbs| 5.7 NM

13

| M8 x 1.25 x 25mm 316 Stainless Socket Cap Bolt|

2

| 100 in./Lbs| 11.3 NM

14

| M8 316 Stainless Washer|

4

| –| –

15

| M8 316 Stainless Flanged Locknut|

2

| 100 in./Lbs|

11.3 NM

6.2.3 Radius End Double Tap Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| RADIUS DOUBLE TAP RAIL ASSEMBLY – EXPLODED VIEW

B

| RADIUS DTR ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| RADIUS DTR ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33” (83.82cm)| 39” (99.06cm)| 45” (114.30cm)| 51” (129.54cm)|

57” (14cm)

ITEM

| DESCRIPTION| QTY| TORQUE SPEC

1

| RADIUS END – DRIVERS SIDE|

1

| –| –

2

| RADIUS END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

8

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

8

| –| –

6

| Anodized Black Saddle Washer|

8

| –| –

7

| M6 316 Stainless Flanged Locknut|

4

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

4

| –| –

9

| Radius Upper Tube – Driver Side|

1

| –| –

10

| Radius Upper Tube – Passenger Side|

1

| –|

–

6.3.1 Flat End Wasteland Assembly

FIGURE

| DESCRIPTION
---|---

A

| FLAT WASTELAND ASSEMBLY – EXPLODED VIEW

B

| FLAT WASTELAND ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| FLAT WASTELAND ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| FLAT END – DRIVERS SIDE|

1

| –| –

2

| FLAT END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

6

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

4

| –| –

6

| Anodized Black Saddle Washer|

4

| –| –

7

| M6 316 Stainless Flanged Locknut|

2

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

3

| –|

–

6.3.2 Flat End Hybrid Death Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| FLAT HYBRID DEATH RAIL ASSEMBLY – EXPLODED VIEW

B

| FLAT HDR ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| FLAT HDR ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

D

| FLAT HDR ASSEMBLY – RADIUS HDR SUPPORT – RK (HIGHLIGHTED IN ORANGE) CLOSEUP DRIVERS SIDE VIEW

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33.70” (85.59cm)| 39.70” (100.83cm)| 45.70” (116.07cm)| 51.70” (131.38cm)|

57.70” (146.55cm)

C4

| 33.08 (84.02cm)| 39.08 (99.26cm)| 45.08 (114.50cm)| 51.08 (129.74cm)| 57.08 (144.98cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| FLAT END – DRIVERS SIDE|

1

| –| –

2

| FLAT END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

6

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

12

| –| –

6

| Anodized Black Saddle Washer|

4

| –| –

7

| M6 316 Stainless Flanged Locknut|

6

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

3

| –| –

9

| Flat Hybrid Death Rail|

2

| –| –

10

| Flat Hybrid Death Rail Support – RK|

1

| –| –

11

| Flat Hybrid Death Rail Support – LK|

1

| –| –

12

| M6 x 1.00 x 25mm 316 Stainless Socket Cap Bolt|

4

| 50 in./Lbs| 5.7 NM

13

| M8 x 1.25 x 25mm 316 Stainless Socket Cap Bolt|

2

| 100 in./Lbs| 11.3 NM

14

| M8 316 Stainless Washer|

4

| –| –

15

| M8 316 Stainless Flanged Locknut|

2

| 100 in./Lbs|

11.3 NM

6.3.3 Flat End Double Tap Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| FLAT DOUBLE TAP RAIL ASSEMBLY – EXPLODED VIEW

B

| FLAT DTR ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| FLAT DTR ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33” (83.82cm)| 39” (99.06cm)| 45” (114.30cm)| 51” (129.54cm)|

57” (14cm)

ITEM

| DESCRIPTION| QTY| TORQUE SPEC

1

| FLAT END – DRIVERS SIDE|

1

| –| –

2

| FLAT END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

8

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

8

| –| –

6

| Anodized Black Saddle Washer|

8

| –| –

7

| M6 316 Stainless Flanged Locknut|

4

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

4

| –| –

9

| Flat Upper Tube [Not Side Specific Can Be Used On Both Driver And Passenger Sides]|

2

| –|

–

6.4.1 Short (aka Rear) End Wasteland Assembly

FIGURE

| DESCRIPTION
---|---

A

| SHORT WASTELAND ASSEMBLY – EXPLODED VIEW

B

| SHORT WASTELAND ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| SHORT WASTELAND ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| SHORT END – DRIVERS SIDE|

1

| –| –

2

| SHORT END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

6

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

4

| –| –

6

| Anodized Black Saddle Washer|

4

| –| –

7

| M6 316 Stainless Flanged Locknut|

2

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

3

| –|

–

6.4.2 Short (aka Rear) End Hybrid Death Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| FLAT HYBRID DEATH RAIL ASSEMBLY – EXPLODED VIEW

B

| FLAT HDR ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| FLAT HDR ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

D

| FLAT HDR ASSEMBLY – FLAT HDR SUPPORT – K (HIGHLIGHTED IN PURPLE) CLOSEUP DRIVERS SIDE VIEW

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33.70” (85.59cm)| 39.70” (100.83cm)| 45.70” (116.07cm)| 51.70” (131.38cm)|

57.70” (146.55cm)

C4

| 33.08 (84.02cm)| 39.08 (99.26cm)| 45.08 (114.50cm)| 51.08 (129.74cm)| 57.08 (144.98cm)
ITEM| DESCRIPTION| QTY|

TORQUE SPEC

1

| SHORT END – DRIVERS SIDE|

1

| –| –

2

| SHORT END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

6

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

2

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

12

| –| –

6

| Anodized Black Saddle Washer|

4

| –| –

7

| M6 316 Stainless Flanged Locknut|

6

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

3

| –| –

9

| Connector Slug|

2

| –| –

10

| Rear Hybrid Death Rail|

2

| –| –

11

| Flat Hybrid Death Rail Support – RK|

1

| –| –

12

| Flat Hybrid Death Rail Support – LK|

1

| –| –

13

| M6 x 1.00 x 25mm 316 Stainless Socket Cap Bolt|

4

| 50 in./Lbs| 5.7 NM

14

| M8 x 1.25 x 25mm 316 Stainless Socket Cap Bolt|

2

| 100 in./Lbs| 11.3 NM

15

| M8 316 Stainless Washer|

4

| –| –

16

| M8 316 Stainless Flanged Locknut|

2

| 100 in./Lbs| 11.3 NM

17

| Hybrid Death Rail Support|

4

| –|

–

6.4.3 Short (aka Rear) Double Tap Rail Assembly

FIGURE

| DESCRIPTION
---|---

A

| SHORT DOUBLE TAP RAIL ASSEMBLY – EXPLODED VIEW

B

| SHORT DTR ASSEMBLY – ASSEMBLED VIEW (36 WOA SPEC)

C

| SHORT DTR ASSEMBLY – TECHNICAL TOP AND SIDE PROFILE MEASUREMENTS

D

| SHORT DTR ASSEMBLY – REAR DTR SUPPORT (HIGHLIGHTED IN BLUE) CLOSEUP VIEW FROM REAR PERSPECTIVE

MEASUREMENT

| 36 WOA ASSEMBLY| 42 WOA ASSEMBLY| 48 WOA ASSEMBLY| 54 WOA ASSEMBLY| 60 WOA ASSEMBLY
C1| 37” (93.98cm)| 43” (109.22cm)| 49” (124.46cm)| 55” (139.70cm)|

61” (154.94)

C2

| 36” (91.44cm)| 42” (106.68cm)| 48” (121.92cm)| 54” (137.16cm)| 60” (152.40cm)
C3| 33” (83.82cm)| 39” (99.06cm)| 45” (114.30cm)| 51” (129.54cm)|

57” (14cm)

ITEM

| DESCRIPTION| QTY| TORQUE SPEC

1

| SHORT END – DRIVERS SIDE|

1

| –| –

2

| SHORT END – PASSENGER SIDE|

1

| –| –

3

| Threaded Slug Cross Connector Assembly (See 5.2 Width Connections)|

8

| –| –

4

| M6 x 1.00 x 45mm 316 Stainless Socket Cap Bolt|

4

| 50 in./Lbs| 5.7 NM

5

| M6 316 Stainless Washer|

16

| –| –

6

| Anodized Black Saddle Washer|

8

| –| –

7

| M6 316 Stainless Flanged Locknut|

8

| 50 in./Lbs| 5.7 NM

8

| Cross Bars (All WOA variants)|

4

| –| –

9

| Connector Slug|

4

| –| –

10

| Double Tap Rail Support|

6

| –| –

11

| Rear Double Tap Rail Support [Includes Isolating Foam Strips For Both Points Of Contact]|

2

| –| –

12

| M6 x 1.00 x 12mm 316 Stainless Socket Cap Bolt|

4

| 50 in./Lbs| 5.7 NM

13

| Short Upper Tube [Not Side Specific Can Be Used On Both Driver And Passenger Sides]|

2

| –|

–

6.5 Double Tap Rail Airdam Assembly

ITEM

| DESCRIPTION| QTY| TORQUE SPEC
---|---|---|---

1

| M5 x .08 x 25mm 316 Stainless Button Head Bolt|

8

| 30 in./Lbs| 3.4 NM

2

| M5 316 Stainless Washer|

8

| –| –

3

| 316 Stainless Tube Clamp Mount|

8

| –| –

4

| M5 316 Stainless Flanged Locknut|

8

| 30 in./Lbs| 3.4 NM

5

| DTR Airdam [SAME HARDWARE REGARDLESS OF ASSEMBLY WOA]|

1

| –| –
FIGURE|

DESCRIPTION

A

| Complete Rack With Airdam Installed View
[NOTE: Flat & Radius DTR Assemblies Use Same Hardware And Only Differ In Hole Distance And Side Design]

B

| Tube Clamp Mounts Installed On Top Rails And Forward Rails Of Lower Assembly

C

| Exploded View Of DTR Airdam Assembly With Hardware Configuration

6.6 Radius Hybrid Death Rail / Wasteland Airdam Assemblies

ITEM

| DESCRIPTION| QTY| TORQUE SPEC
---|---|---|---

1

| M5 x .08 x 25mm 316 Stainless Button Head Bolt|

8

| 30 in./Lbs| 3.4 NM

2

| M5 316 Stainless Washer|

8

| –| –

3

| 316 Stainless Tube Clamp Mount|

8

| –| –

4

| M5 316 Stainless Flanged Locknut|

8

| 30 in./Lbs| 3.4 NM

5

| HDR / Wasteland Airdam [SAME HARDWARE REGARDLESS OF ASSEMBLY WOA]|

1

| –| –
FIGURE|

DESCRIPTION

A

| Complete Rack With Airdam Installed View [NOTE: All HDR & Wasteland Assemblies Use Same Hardware]

B

| Tube Clamp Mounts Installed On Front And Middle Rails

C

| Exploded View Of HDR / Wasteland Airdam Assembly With Hardware Configuration

D

| Tube Clamps (Highlighted Pink) Should Be Installed Through Small Slot Between Mounting Plate And Crossbar Tube On Outermost Clamps, Then Rotated To Correct Orientation (As Pictured In Figure B) BEFORE Airdam Is Positioned To Help Ease Installation

6.7 Complete Rack Assembly Example

EXPLODED VIEW COMPONENTS

ITEM| DESCRIPTION|

QTY

1

| HINGE MOUNT ASSEMBLY – EXPLODED|

6

2

| RADIUS DTR END ASSEMBLY – EXPLODED|

1

3

| INTERMEDIATE DTR ASSEMBLY – EXPLODED|

3

4

| SHORT END ASSEMBLY – EXPLODED|

1

ASSEMBLED VIEW COMPONENTS

ITEM

| DESCRIPTION| QTY

5

| HINGE MOUNT ASSEMBLY – ASSEMBLED|

6

6

| RADIUS DTR END ASSEMBLY – ASSEMBLED|

1

7

| INTERMEDIATE DTR ASSEMBLY – ASSEMBLED|

3

8

| SHORT END ASSEMBLY – ASSEMBLED|

1

FIGURE|

DESCRIPTION

A

| RADIUS FULL RACK ASSEMBLY – EXPLODED ISOMETRIC VIEW

B

| RADIUS FULL RACK ASSEMBLY – ASSEMBLED ISOMETRIC VIEW

C

| RADIUS FULL RACK ASSEMBLY – SIDE VIEW

7. Maintenance and Care

• Inspect your rack for any signs of wear or damage each use. 
• Ensure all bolts are tight and the rack is secure each use. 
• Ensure all loads are secured each use and check periodically throughout your journey. 
• Do not exceed the recommended cab roof weight limit specified for your particular vehicle. ZombieRacks can carry more than most vehicle roof weight limits, so consult your owner’s manual for your specific application. 
• Clean with mild automotive soap and water with a microfiber towel. Avoid cleaning with abrasive materials like acetone / mineral spirits as these can damage the finish. 
• For extended protection we recommend an easy to apply ceramic coating which can be purchased on our website. 
• : DO NOT UNDER ANY CIRCUMSTANCES USE A ZOMBIERACKS PRODUCT THAT SHOWS SIGNS THAT IT IS UNFIT FOR USE, EVER.

8. Warranty and Customer Service

• All ZombieRacks systems come with a limited lifetime warranty. Refer to warranty documentation on our website at the bottom of the web page under policies for more details.
• For customer service or support, contact our team at 1(866) 906-0930 or email [email protected]

  ZombieRacks is not responsible for damage or injury resulting from improper installation or use. Always follow local traffic and safety regulations, do not overload your rack and operate your vehicle in a safe manner at all times.

Enjoy Your ZombieRacks Universal Expandable Cargo Rack System Safely And Be Good To Each Other Out There!

– Entire ZombieRacks Team

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