SHERPA The Cub Tundra Camper Installation Guide
- June 2, 2024
- SHERPA
Table of Contents
**SHERPA The Cub Tundra Camper Installation Guide
**
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 6 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
SIDEPLATES
Required Components:
- 8x 1/4”-20 x 1”
- 8x 1/4” Flat Washers
Fasten the sideplates to the ends of the two mounting-foot cross members using
the supplied 1” socket buttons and flat washers in the designated mounting
slots, as pictured above. Recall that the brackets come in pairsdenoted by
the ‘F’ (front) or ‘R’ (rear).
Note the small notch in the bottom corner of the bracket – this will face
toward the front of the vehicle when installed.
The cross member should sit relatively centered in the slot, but may shift slightly due to small variations in roof construction or shifting during the drilling step. More on that later.
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.
TEMPLATE 1
Remove the trim from the roof gutter to reveal the foam layer beneath. Position the assembled rack on the roof of your vehicle.
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
TEMPLATE 2
If the vehicle is equipped with the panoramic roof, ensure that the placement of the cross member attached to the mounting brackets will not interfere with the roof’s operation throughout its entire range of motion. This is achieved by placing the rack on the vehicle and sliding the cross member in the sideplate slot while cycling the panoramic roof slowly.
The location of this rear mounting bracket changes based on the version of The Cub that the customer has purchased.
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:
- 8x 1/4”-20 x 1” Socket buttons
- 8x 1/4” Flat washers
- 2x 53” 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.