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FVC TR0109B Installation Manual

Transit van safari rack - 148” high roof (drop front)
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TRANSI T VAN SAFARI R ACK - 1 48 " HI GH RO OF ( DRO P FRO NT)
TR010 9B
INSTALLATION
GUIDE
F L AT L I N E VA N C O • S U P P O R T @ F L AT L I N EVA N C O . C O M • 8 8 8 - 6 6 7- 5 5 7 6
TOOLS REQUIRED
(NOT INCLUDED)
+
MEASURING TAPE
+
QWICK CLAMPS
+
3/8" WRENCH OR SOCKET
+
7/16" WRENCH OR SOCKET
+
9/16" WRENCH OR SOCKET
+
5/32" ALLEN WRENCH
INSTALL INFO
TIME TO INSTALL THIS PRODUCT: 3-4 HOURS
Additional help is suggested for a few of the install
steps.
BEFORE YOU START
Please inspect the product and packaging upon
delivery to ensure there are no issues and that all
parts and hardware are accounted for.
Contact us ASAP if anything is missing at:
support@flatlinevanco.com
0 1

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Summary of Contents for FVC TR0109B

  • Page 1 INSTALLATION GUIDE TRANSI T VAN SAFARI R ACK - 1 48 ” HI GH RO OF ( DRO P FRO NT) TR010 9B TOOLS REQUIRED (NOT INCLUDED) MEASURING TAPE QWICK CLAMPS 3/8” WRENCH OR SOCKET 7/16” WRENCH OR SOCKET 9/16” WRENCH OR SOCKET 5/32”...

  • Page 2: Before You Start

    BEFORE YOU START All Flatline Van Co products must be properly assembled and secured before attaching to your vehicle. Improper attachment could result in an automobile accident, and could cause serious bodily injury or death to you or to others involved. You are responsible for assembling and securing Flatline Van Co products to your vehicle, checking the mounting points and attachments prior to use, and regularly inspecting the products for wear and or damage.

  • Page 3: Package Contents

    PACKAGE CONTENTS DROP DOWN WELDMENT SIDE RAIL (34”) SIDE RAIL (20.5”) DROP FRONT BASKET REAR BASKET QTY: 4 QTY: 2 QTY: 1 QTY: 1 QTY: 1 FLOOR SECTION FAN SIDE PANEL FLOOR SECTION FAN COVER SAFARI FOOT BRACKET F45 AWNING BRACKET FLOOR SECTION 1 QTY: 8 QTY: 3...
  • Page 4 HARDWARE 5/16” BONDED SEALING 3/8-16 X 1 CARRIAGE BOLT M8-1.25 HEX HEAD SCREW 1/4-20 T-NUT 3/8-16 NYLON LOCKNUT WASHERS QTY: 26 QTY: 8 QTY: 37 QTY: 26 QTY: 8 1/4-20 X 0.75 FLANGED HEX 1/4-20 X 0.75 FLANGED BUTTON 1/4-20 X 0.5 FLANGED BUTTON 3/8 SCREW FLAT WASHER 1/4-20 CLIP NUT HEAD SCREW...
  • Page 5 INSTALL TOOLS REQUIRED FOR THIS STEP: CHISEL DIE GRINDER OR METAL FILE STEP | 01 LAYOUT AND INSTALL PREP 1.1 Remove Mounting Hole Caps: Use a heat gun on a low temperature setting to loosen up the adhesive that holds the mounting hole caps to the top of the van.
  • Page 6 TOOLS REQUIRED FOR THIS STEP: 13MM BOX WRENCH OR SOCKET CAULKING GUN STEP | 02 FOOT BRACKET INSTALL 2.1 Install Foot Brackets: Secure the Foot Brackets to the roof by tightening down M8 Bolts with loctite and 5/16” Bonded Sealing Washers (FIG 5+6). 2.2 Apply Sealant: Apply a small bead of exterior waterproof sealant around the outside of each landing pad (FIG 7).
  • Page 7 5/32” ALLEN WRENCH TOOLS REQUIRED FOR THIS STEP: 9/16” WRENCH OR SOCKET STEP | 03 SIDE RAIL ASSEMBLY 3.1 Assemble Side Rails: Insert a Bayonet into the end of a 34” Side Rail (FIG 8+9) and use (2) 1/4-20 x 0.75 Flanged Button Head Screws (not the shorter ones) to loosely secure the Bayonet in place.
  • Page 8 QWICK CLAMPS TOOLS REQUIRED FOR THIS STEP: 3/8” WRENCH OR SOCKET 7/16” WRENCH OR SOCKET STEP | 04 SIDE RAIL ASSEMBLY 4.1 Fasten Side Rails Together: Secure the connection with a 1/4-20 Flanged Hex Bolt, Washer and Nylon Locknut. Insert the bolt through the smaller hole inside the larger wire pass- through hole (FIG 10).
  • Page 9 9/16” WRENCH OR SOCKET TOOLS REQUIRED FOR THIS STEP: STEP | 05 SIDE RAIL INSTALL 5.1 Mount Side Rails to Van Rails: With assistance, lift the Side Rail Assembly onto the roof. Align the Side Rail Assembly with the mounting holes of the Foot Brackets and secure loosely using 3/8-16”...
  • Page 10 TOOLS REQUIRED FOR THIS STEP: 5/32” ALLEN WRENCH QWICK CLAMPS 3/8” WRENCH OR SOCKET 7/16” WRENCH OR SOCKET STEP | 06 ATTACH BASKETS TO RAILS 6.1 Attach Front and Rear Baskets: With help, carefully attach the Front Basket to the protruding Bayonets and secure the connections using (2) 1/4-20 x 0.75 Flanged Button Head Screws (not the shorter ones) for the Bayonets and a 1/4-20 Flanged Hex Bolt, Washer and Nylon Locknut for the Side Rail...
  • Page 11 TOOLS REQUIRED FOR THIS STEP: 3/8” WRENCH OR SOCKET 7/16” WRENCH OR SOCKET STEP | 07 ATTACH DROP FRONT 7.1 Attach Drop Front: The Drop Front mounts to the underside tray of the Front Basket Weldment. You will need to maneuver it around your antenna to get it in place, so having a second person helps immensely for this step.
  • Page 12 TOOLS REQUIRED FOR THIS STEP: MEASURING TAPE 9/16” WRENCH OR SOCKET STEP | 08 INSTALL AWNING BRACKETS 8.1 F45 Awning Brackets (optional): If you purchased a Fiamma F45 Awning with your rack, install the (3) Awning Brackets at this time using (2ea) 3/8-16” Carriage Bolts, Flat Washers and Nylon Locknuts.
  • Page 13 TOOLS REQUIRED FOR THIS STEP: 9/16” WRENCH OR SOCKET STEP | 09 INSTALL LADDER BRACKET 9.1 Side Ladder Bracket (optional): If you purchased a Side Ladder with your rack, install the Side Ladder Bracket at this time using (2ea) 3/8-16” Carriage Bolts, Flat Washers and Nylon Locknuts.

  • Page 14: Step | 10 Install Crossbars

    TOOLS REQUIRED FOR THIS STEP: MEASURING TAPE 7/16” WRENCH OR SOCKET STEP | 10 INSTALL CROSSBARS 10.1 Attach Crossbars: Using (4ea) 1/4-20 Flanged Hex Bolts with Loctite (FIG 24), attach Crossbars to the rack in the locations shown in FIG 25. Be sure to measure both sides to ensure that the crossbars are square.
  • Page 15 TOOLS REQUIRED FOR THIS STEP: STEP | 11 PREP FOR PANELS 11.1 Attach Clip Nuts to Baskets: Install the Clip Nuts to the Front and Rear Basket locations as shown in FIG 26. NOTE - The flat side of the Clip Nut should be facing upwards (FIG 27) F I G 2 6 F I G 27...
  • Page 16 TOOLS REQUIRED FOR THIS STEP: STEP | 11 PREP FOR PANELS 11.2 Layout T-Nuts: Consider the layout plan of your roof accessories and install T-Nuts into the available slots of the Crossbars as shown in FIG 28. See FIG 29 for amounts of T-Nuts needed per slot if using exclusively decking panels.
  • Page 17 TOOLS REQUIRED FOR THIS STEP: REAR FLOOR SECTION STEP | 12 INSTALL FLOOR PANELS BACK FLOOR SECTION FAN SIDE PANEL 12.1 Install Floor Panels: Begin to layout your Decking Panels FLOOR SECTION FAN COVER along the locations shown in FIG 30. Adjust the T-Nuts as FLOOR SECTION 1 necessary to line up with the available pill slots of the Decking Panels (FIG 31).
  • Page 18 TOOLS REQUIRED FOR THIS STEP: 5/32” ALLEN WRENCH STEP | 12 INSTALL FLOOR PANELS 12.2 Install Floor Panels: Note that the front and rear-most CLIP NUT MOUNT panels have pill slots for attaching to the Clip Nuts installed earlier (FIG 32). Use the 1/4-20 x 0.5” Flanged Button Head Screws for the Decking Panels that attach to Crossbars, and the longer 0.75”...

  • Page 19: Step | 13 Final Adjustments

    TOOLS REQUIRED FOR THIS STEP: 3/8” WRENCH OR SOCKET 7/16” WRENCH OR SOCKET 9/16” WRENCH OR SOCKET 5/32” ALLEN WRENCH STEP | 13 FINAL ADJUSTMENTS 13.1 Tighten Fasteners: Once you’ve got all of the floor sections bolted down, do a once-over of all fasteners on the rack to ensure they are tight and secure.
  • Page 20 FVC (and see) from you! Head to the products and following along and we will make it right. FVC is product page and click “Leave a company of van and outdoor with your adventures. Tag us Review.”...