SHERPA The Storm Roof Rack Instruction Manual
- June 2, 2024
- SHERPA
Table of Contents
The Storm Roof Rack
Instruction Manual
HARDWARE CHECKLIST
Exact hardware color counts may vary based on the options selected at
checkout. 
BEFORE YOU BEGIN
The installation of this rack requires you to drill into your roof. If you are not comfortable with this, please contact a reputable installer.
USING TNUTS
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 cross member 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:
8x M8 x 16 Hex bolt
8x M8 Flat Washers
2x Rivet Spacer – Contour
2x Rivet Spacer – Flat
Loosely fasten the supplied rivet spacers to the bottom (longer) flange of the
mounting brackets using the supplied M8 hex bolts and M8 flat washers. The
contour spacers go on the front mounting brackets, and the flat spacers go on
the rear mounting brackets. The brackets are designated with ‘F’ and ‘R’,
respectively.
MOUNT ASSEMBLY 02
Required Components:
8x 1/4”-20 x 9/16”
8x 1/4” Flat Washers
8x 1/4” Tnuts
Secure the tops of the mounting bracket pairs to the wide faces of the cross
members using the supplied T-nuts, 9/16” 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 later.
Later, the rack can be centered on the roof by measuring the distance from the
ends of the cross member to the inside-edge of the mounting brackets on either
side of the vehicle.
SIDEPLATES
Required Components:
8x 1/4”-20 x 1” Socket Button
8x 1/4” Flat washer
Fasten the sideplates to the ends of the three mounting-foot cross members
using the supplied 1” socket buttons and flat washers in the designated
mounting slots. Refer to the next page for more details on which slots to
use.
TEMPLATE
Position the assembled rack on the roof of your vehicle. Move the mounting
brackets along the cross members so that the rivet spacers sit centered in the
gutters of the roof.
Adjust the brackets along the length of the cross member so that the rivet
spacer sits flat and is relatively centered in the gutter. Likewise, the
bottom edge of the sideplate should fit nicely along the curvature of the
vehicle with a consistent gap of around 1/2”.
If it does not, move the rack (or cross members in the slot) until the rack
looks centered and placed properly.
The properly aligned rack will serve as the drilling template. Follow the next
steps to ensure the best fitment of the rack.
WIND FAIRING
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 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.
The installation of the wind fairing can assist in ensuring the rack is
centered and placed correctly on the vehicle.
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
With the rack on the truck, mark the position for each rivet spacer USING 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 are important in making sure that the rack fits your vehicle
correctly. Measure 3 times, check 4 times. Be extremely careful not to drill
through your airbags – using a drillstop on your drill bit can help prevent
this by limiting the travel of the drill bit.
With the holes marked, the rack can be removed from the roof. It is worth
double checking that the rack sits in its final configuration before marking,
removing, and drilling. The rivet spacers can also be removed from the
mounting brackets on the rack to assist the following steps.
Once you have your drilling points marked with the punch, drill the hole using
a 3/16” drill bit. A pilot hole using a smaller drill bit – such as a 1/8” or
5/32” bit – can be drilled first. DO NOT allow the drill bit to plunge after
the hole is drilled. The headliner is only a small distance below the surface
of the roof. Be sure to keep the drill bit as straight as possible while
drilling.
AGAIN, DO NOT allow the drill bit to plunge after the hole is drilled. Check
that the rivets will pass through the rivet spacer and the drilled hole. A
tight fit is preferred in order to solidify the connection between the vehicle
and the rack.
RIVETS
Required Components:
8x 3/16” Rivets
1x Rivet Tool
Next, secure the rivet spacers using the holes you have drilled. It is
important that the spacer is tight against the roof and free of debris before
riveting it down. Apply a small amount of silicone in and around the rivet
spacer and rivet to seal up the hole in the roof. Using your rivet tool, clamp
down on the rivet as close to the head as possible. The mandrel of the rivet
will shear off once it is installed and should be flush with the head.
WE RECOMMEND PLACING THE FULL RACK BACK ON THE ROOF FOR THE REMAINING
STEPS. IMAGES ARE SHOWN WITHOUT SIDES FOR ILLUSTRATIVE PURPOSES.
MOUNTS
Required Components:
12x M8 Bolts
12x M8 Flat Washers
Next, re-install the assembled rack on the roof, allowing the mounting
brackets to rest on the rivet feet. If these do not line up, loosen the
hardware that secures the mounting
bracket to the cross member and adjust as needed. Fasten the mounting bracket
to the rivet spacer using the M8 x 16 hex bolt and washers with the addition
of a drop of blue threadlocker on the bolt threads supplied with the rack.
Once satisfied with how the rack sits on the vehicle, tighten down all
hardware between the cross members and the mounting brackets. The rack should
not need adjusting after this step.
CROSS MEMBERS
Required Components:
20x 1/4”-20 x 1” Socket buttons
20x 1/4” Flat washers
5x 56” Cross members
Secure all of the remaining cross members 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 half-fairing applications, an
additional slot has been added between the front-mounting-bracket cross member
and the wind fairing to accomodate a cross member for the lightbar and
corresponding Sherpa lightbar brackets.
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.