Let's Go Aero BLACK BOX Assembly, Installation And Operation Instructions

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BLACK BOX

Slide-Out Enclosed Cargo Carrier System

Set Item Product

PRODUCT MANUAL

Installation & Safe Use Operation Highlights

Fits 2” size receiver hitches.

Rated for 300 lbs of cargo payload. 160 lbs empty weight.

Class II minimum tow rating required; Class III recommended.

BlACK BOX SYSTEM - ASSEMBLY, INSTALLATION, AND OPERATION INSTRUCTIONS:

Description Page

FlatPipe™ Spine Assembly & Installation on Hitch........................................... 2

Safe Use & Operation ........................................................................................ 3

Rack Parts & Assembly ...................................................................................... 4

AerFoil Lid Parts & Assembly ............................................................................. 11

Warranty & Registration ..................................................................................... 14

For More Information & Accessories, Visit our Website - www.LetsGoAero.com

For Technical Support & Product Questions Contact Us at 877-464-2376 or 719- 630-3800

BBOXManual-042117Rev

Email: [email protected]

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FLATPIPE™ SPINE ASSEMBLY AND INSTALLATION

Qty. Description A 1 FlatPipe™ Spine B 2 Retainer Clip C 1 5/8” Silent Hitch Pin D 1 5/8” Silent Hitch Pin®

(hand-tighten version) E 1 5/8” Lock Washer F 1 5/8” Plastic Bushing G 2 5/8” Spring Nut H 2 End Cap, 2” Square J 1 Wax K 2 Rubber Bumper L 1 5/8” Flat Washer

STEP 1 Install two spring nuts [G] as shown.

The Spine shank end contains two mounting holes. The ideal hole to use is the second hole in from the end. If the shank bottoms out inside the receiver hitch, or if you need maximum clearance for a tailgate, use the ﬁrst hole in from the end.

NOTE: For proper cargo carrier balance, there is a 3° pitch on the Flat Pipe. Be sure when installing your shank into the receiver hitch that the shank is right side up and that the 3° faces upward.

Shank End

STEP 2

Slide the shank end of the Spine [A] into the receiver hitch aligning the mounting hole with the hole in the receiver hitch. Attach with Silent Hitch Pin and a 5/8” Lock Washer [C,E] by threading the Pin into the Spring Nut [G]. Tighten (30 ft.lbs. torque)and attach Pin Clip [B].

REQUIRED TOOL: 7/8” WRENCH

3° Pitch

FIRST

SECOND

INSERT INTO VEHICLE

HITCH RECEIVER

Hitch Receiver

Shank End

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STEP 3

Apply Wax [J] by rubbing the Wax block on all four sides of both tubes. Install two rubber bumpers [K] (one onto each ﬁxed tube). The remaining hand-tighten Silent Hitch Pin, Bushing and Retainer Clip [D,F,G] will be used to secure the Black Box Rack to the FlatPipe Spine in a later step.

End Caps [Factory Installed] Rubber Bumpers Wax

SAFE USE OPERATION

Be sure to follow these guidelines to prevent possible hazards from misuse.

Vehicle and Hitch Receiver Compliance

This Cargo Carrier ﬁts 2" size hitch receivers and is rated for a Class II tow capability or higher. Before using this product, consult your vehicle and hitch receiver owner manual(s) for details on your tow and tongue weight parameters. Be sure that they are compatible with Black Box’s weight speciﬁcations.

Tongue Weight Compliance

The Black Box and its cargo create a combined weight that creates direct downward pressure on the hitch receiver’s tongue. This downward pressure is the tongue weight. Tongue weight is one of the two critical weight rating factors of your tow rating’s classiﬁcation. Never exceed your vehicle and hitch receiver’s tongue weight speciﬁcation.

Black Box Weight and Load Parameters

The Black Box weights 160 lbs empty. To determine your available load weight in accordance with your vehicle and hitch receiver’s tongue weight rating, subtract Black Box’s weight from your identiﬁed tongue weight rating. The difference represents your vehicle and hitch receiver’s available load weight. The Black Box is rated for up to 300 lbs of cargo payload weight. Position heaviest cargo in the center of the carrier and lighter cargo to the outside perimeter

About Slide Out & Clearance Adjustment Of Carrier

To telescope the Black Box, remove the Hand Tighten Silent Hitch Pin® from the slide out pin hole. Verify that the Safety Cable is secured and then slide the frame to the rear. For added clearance, adjust the position of the Hat Brackets along the Frame’s Female Slide Tubes. Be sure to adhere to NO USE AREA distance of 3.5 inches rearward from Spine’s vertical plate along the frame tubes.

TIP: Secure your gear during transit, contents may shift causing damage to gear and/or cargo carrier. It is user responsibility to properly secure cargo. Optional tie down items are available at Let’s Go Aero for purchase.

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RACK PARTS LIST & ASSEMBLY OVERVIEW

Tools Needed:

9/16" Wrench and Socket 7/16" Wrench and Socket 5/32” Hex Key

3/16” Hex Key Center Punch Drill and Drill Bits

TWINTUBE FRAME MOUNT

QTY. DESCRIPTION

M N O P Q R S

FEMALE TUBES

FRAME ANGLES

HAT BRACKETS

5/16 CARRIAGE BOLTS

5/16 WASHERS

5/16 NUTS

SAFETY CABLE WITH QUICK LINK

END CAPS WITH REFLECTORS, 2-1/4”

RACK & SIDE PANEL

QTY. DESCRIPTION

U-TUBE

FLOOR PANEL

SIDE TUBE

END TUBE (OPEN RACK ONLY)

JOINT CONNECTOR BOLT 2.5”

M6 X 15 SOCKET HEAD BOLT

M6 WASHER

M6 NYLOCK NUT

SOCKET HEAD BOLT 1.5”

PIN NUT

SQUARE END CAPS

CROSS TUBE

PLUG

SOCKET HEAD BOLT 1.6

SIDE PANEL

END PANEL WITH HINGES

END PANEL WITH PULL LATCHES

1/4-20 X 3/4 BOLT

K-LATH SELF TAPPING SCREW

If you are missing any items, contact your sales

agent if the product was assembled by them. If not, or if purchased from Let’s Go Aero, please

LIGHT KIT

QTY. DESCRIPTION

LED LIGHTS

WIRE HARNESS

LED LICENSE PLATE BRACKET

LED MOUNT BRACKET

6mm HEX BOLT

6mm NYLON BOLT

6mm WASHER

AERFOIL LID (Black Box Cover)

QTY. DESCRIPTION

POLYPRO COVER SHEET

BULKHEAD

AAA BBB CCC DDD

EEE

FFF

GGG

HHH

JJJ

KKK

LLL

XX YY

III

BULK HEAD WITH LATCH KEEPER

.75” WASHER

BALANCE CABLE

1/4-20 NYLOCK NUT

HANDLE

1/4-20 JOINT SOCKET HEAD BOLT

1/4-20 X 1.25 BOLT

1-4-20 PIN NUT (BLACK)

43” AERFOIL BAND

BAND SPRING

.3” X 1 WASHER

1/4 X 1 FENDER WASHER

1/4-20 X 1.5 BOLT

10-24 X 1.25 PHILLIPS SCREW

10-24 NYLOCK NUT

3/16 X 1 FENDER WASHER

NOTE: End Tubes [X] and excess Square End Caps [EE] are for open rack assembly only. For Black Box Enclosed Cargo Carrier you may discard these pieces or save for open rack

use. See GearCage Rack assembly manual for open rack assembly.

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FLAT PIPE

FRAME MOUNTING

PLATFORM

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STEP 1

Slide the Female Tubes [M] over FlatPipe Spine [A]. NOTE: The holes at the end of the Spine and the Females Tubes must line up for proper assembly. Using 5/16 Carriage Bolts, 5/16 Washers, and 5/16 Nuts [P, Q, R] attach the Frame Angles [N] and the Hat Brackets [O] to the Female Tubes. The vertical portions of the frames angles should face the exterior of the carrier and the Hat Brackets bolting to the frame angles from underneath the females tubes and spine. Install the Safety Cable [S] by placing the looped end (the side without the Quick Link) in between the Hat Bracket and Frame Angle (located closest to the vehicle, on the passenger side, using the side of the Hat Bracket that faces the interior of the Spine). Hand Tighten all connections at this time. Install End Caps with Reﬂectors [T] at the ends of the exposed Female Tubes.

Align to Flat

Pipe Spine

STEP 2

Attach the Flat Pipe Frame Mount to each Cross Tube [FF] using a 1.6” Socket Head Bolt, M6 Washer and a M6 Nylock Nut [HH, AA, BB]. Hand tighten only at this time.

FLAT PIPE

FRAME MOUNT

AA BB

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STEP 3

STEP 3: Using a M6 Washer and a M6 Nylock

Nut [AA, BB] with a 2.5” Joint Connector Bolt [Y] join two (2) Floor Panels [V] (excluding the third, center Floor Panel which will be attached in the next step), four (4) U-Tubes [U], to the assembled Cross Tubes [FF] and Frame Angles [N] of the Flat Pipe Platform. Continue to hand tighten only at this time.

Press four End Caps [EE] into ends of each Cross Tube [FF].

FLAT PIPE

FRAME

MOUNT

AA BB

STEP 4

Place the last Floor Panel [V] in the center on top of the U-Tubes [U]. Use M6 x 15 Socket Head Bolts, M6 Washers, & M6 Nylock Nuts [Z, AA, BB] at each of the six (6) locations on the underside of the panel to secure the center to the outside panels. Hand tighten only at this time.

AA BB

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STEP 5

Using a 1.5” Socket Head Bolt [CC] and Pin Nut [DD] on the two holes at the ends of the tubes only, connect the Side Tubes [W] and Side Panels [II] to the rack frame by dropping the Socket Head Bolt through the top of the Side Tube down through the Side Panel [Figure 1].

NOTE: There are two holes of different sizes at each end of the side tubes, the larger holes should face upwards to allow the head of the bolt pass through the top and then rest on the smaller hole on the bottom of the interior of the tube [Figure 2].

Finish connecting the ends Side Panels and Tubes to the U-Tubes [U] by placing a Pin Nut [DD] Horizontally through the holes at the end of the U-Tube and then securing the Socket Head Bolt [CC] through the treading in the Pin Nut. Cap these locations (4) with provided Rubber Plugs [GG].

NOTE: For an easier match the Pin Nut is designed with a ﬂat head slot to illustrate the direction of the internal thread. The knotted end should rest on the edge of the U-Tubes [U] hole as shown [Figure 3].

[Figure 1]

[Figure 3]

Large Hole

Small Hole

[Figure 2]

Connect the center portions of the Side Tubes [W] and Panels [II] with 1.5” Joint Connector Bolts [Y] and Pin Nuts [DD] (These bolts will NOT pass through the Side Tubes as the Socket Head Bolts [CC] did at the ends of the tube).

Hand tighten only at this time.

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STEP 6

[Before] [Figure 3] [Figure 4]

With the Side Tubes and End Tubes in place. Un-bolt and remove the two (2) 2.5” Joint Connector Bolts [Y] at each end of the rack allowing the bottom lip of the End Panels [JJ] and [KK] to slip between the Cross Tubes [FF] and U-Tubes [U] [Figure 3]. The End Panel [JJ] that includes Hinge hardware must be installed on the Drivers Side of the Vehicle. With the holes aligned, re-insert the Joint Connector Bolts [Y] [Figure 4].

Using two (2) Joint Connector Bolts [Y] and two (2) Pin Nuts [DD] on each side, connect the End Panels [JJ] and [KK] to the Side Tubes [W] by passing the Bolt through over-hanging edge to the base to of the End Panel and then threading the bolt through the Pin Nut on the interior of the Side Tube. Secure and tighten all hardware from previous steps of the Rack and Side Panel installation.

Locate two 3/16” dia. holes in each end panel. Center punch an indentation at each hole center. Drill 1/8” dia. holes into end tube and u-shaped tube. Insert and tighten four self-tap screws [C].

NOTE: Tip of screws [C] are self-

drilling as well. You may choose

to power drive the screws without

pre-drilling if you have the tools and

skill to do so.

STEP 7

Insert the second Spring Nut [G] into the forked end of the Spine [A] (customer choice of side, only one side is needed) [Figure 5].

[Figure 4]

STEP 8

Insert the Silent Hitch Pin With Handle [D] and Plastic Bushing [F] on the forked end of the Spine [A] containing the second Spring Nut [G] inside. The Pin should be inserted so that it passes through the block portion of the Spring Nut ﬁrst and then exiting through the spring. Tighten ﬁrmly to engage threading and apply Retainer Clip [B] as shown.

Apply the 2-1/4” End Caps [T] with Reﬂectors to the exposed end of the Spine [A] using a Rubber Mallet.

CUSTOMER CHOICE OF SIDE

Never operate the vehicle without the hand-tighten Silent Hitch Pin

properly engaged to prevent the carrier from sliding while in transit.

Failure to do so may result in bodily injury and property damage.

WARNING:

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STEP 9

Optional Safety Cable Position

Connect the Quick Link Side of the Safety Cable [S] to one of the available hole positions located on the frame of the Flat Pipe Spine [A].

WARNING:

DO NOT ALLOW HAT

BRACKETS [O] TO

The Safety Cable prevents the Black Box rack from sliding off the Spine when telescoped. The rack may be slide out when parked for vehicle hatch access only. Never move the vehicle while the carrier is slid out. Failure to engage the

Safety Cable may result in bodily injury and property damage.

OVERLAP WARNING

LABEL ON FEMALE TUBE.

WARNING:

STEP 10

Un-Bolt LED Light Hardware supplied on the LED Lights [NN] and then reattach onto LED Mount Bracket [QQ]. For the drivers side of the vehicle only, also include License Plate Brackets [PP] as shown. [See Drivers Side Illustration]

Use 6 mm Hex Bolts [RR], 6 mm Nylon Nuts [SS], and 6 mm Washer [TT] to install License Plate (Customer Supplied License Plate Not Included) onto License Plate Brackets [PP] as shown.

On the side of the rack furthest away from the vehicle, use 1/4-20 X 3/4 Bolts [LL], .75” Washers [XX] and 1/4-20 Nylock Nuts [ZZ] to install LED Light Brackets [QQ] with mounted hardware and LED Lights [NN] onto the Rack through the Side Panel [II] and Floor Panel [V]. On the drivers side only, include one Balance Cable [YY] loop end between the LED Mount Bracket [QQ] and the .75” Washer [XX]. [See Drivers Side Illustration]

On the other side of the rack on the side closest to the vehicle (where the LED lights have not been installed), secure the Side Panels [II] to Floor Panels [V] using 1/4-20 X 3/4 Bolts [LL], .75” Washers [XX] and 1/4-20 Nylock Nuts [ZZ] in the same manor excluding the LED lights. The second Balance Cable [YY] should also be included between the Side Panel and Washer on the drivers side only.

Connect LED Lighting to the Wire Harness [OO] (not shown) with the yellow wire connected to the drivers

side and the Green Wire connected to the passenger side of the vehicle. Weave Wire Harness through the

underside of the Black Box Rack to prevent wire drag. Connect the Wire harness to the Vehicle Trailer Light Connection on rear of the Vehicle.

Drivers Side

NOTE: The hole location furthest from the vehicle is recommended for maximum slide out.

SS TT

CUSTOMER SUPPLIED

LICENSE PLATE

(NOT INLCUDED)

Passenger Side

CUSTOMER SUPPLIED

LICENSE PLATE

(NOT INLCUDED)

FAILURE TO PROPERLY CONNECT WIRES TO THE

WIRE HARNESS WILL RESULT IN MISMATCHED STOP/

TURN LIGHTS AND IMPROPER SIGNALING.

WARNING

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AERFOIL LID PARTS & ASSEMBLY OVERVIEW

REQUIRED TOOLS:

GGG

BBB

III

DDD

5/32” ALLEN WRENCH RUBBER MALLET

LLL

7/16” WRENCHES PHILLIPS SCREWDRIVER,

JJJ

AAA

HHH

HAMMER 3/8” WRENCH

FFF

KKK

CCC

STEP 11

Unfold AerFoil Cover [UU] and place face-up. Install Handle [AAA] using two (2) each 10-24 x

1.25 Phillips Screws, 10-24 Nylock Nuts, 3/16 X 1 Fender Washers [JJJ, KKK, LLL]. [Figure 7]

[Figure 7]

KKK

JJJ

LLL

AAA

EEE

TOOL: 5/32” HEX WRENCH

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STEP 12

Passenger Side

Place the AerFoil face down so the inner groves are exposed. Unfold Bulk

Heads the pre-installed Joint Connector Bolt

[BBB] from the ends of the Bulk Heads. Insert the Bulk Heads into the

groove near the edge of the AerFoil Cover

line faces the interior of the carrier

[Figure 6]. One Bulk Head [WW]

includes pre-installed silver Latch

Keepers, be sure this Bulk Head is placed on the Passenger side of the

vehicle

[VV] and [WW] and remove

[UU] so the Bulk Heads cut

DDD

BBB

[Figure 6]

Cut Line

Drivers Side

AAA

Re-Insert Joint Connector Bolts [BBB] through the pre-installed Pin Nuts

[DDD] and tighten.

STEP 13

NOTE: This step will be easiest if someone

assists you.

Form AerFoil Cover [UU] around Bulk Heads [UU] inserting edges of Bulk Heads into groove of cover as you go. Attach at remaining two corners with pre-installed Pin Nuts [DDD] and Joint Connector Bolts [BBB] using the same method used in STEP 12.

STEP 14

Place the AerFoil Lid on top of cage. You should be able to engage the Adjustable Pull Latches pre-installed to End Panel

[KK] once the Lid is positioned properly.

BBB

TOOLS: 3/8” WRENCH, PHILLIPS SCREWDRIVER, DRILL, 1/4” BIT.

TOOL: 5/32” HEX WRENCH

DDD

NOTE: If the “catch” of the Pull Latch does not meet the Latch Keepers pre-installed on Bulk Head

raised by spinning the “catch” counter clockwise or vice versa to be lowered.

NOTE: While Let’s Go Aero takes time to inspect and clean all

products before they leave our facility, some Plastic Shavings

may fall from AerFoil lid during the unpacking assembly

process. These are a normal result of the manufacturing

process and are knocked loose during shipment.

[WW] the “catch” can be

Latch Keeper

Adjustable Pull Latch

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STEP 15

NOTE: This step will be easiest if

someone assists you.

Attach the top of the Hinges located on End Panel

on the

Bolts and 1/4-20 Nylock Nuts

[JJ] to the Bulk Head [VV]

AerFoil Lid using 1/4-20 X 1.25

[CCC], .3” X 1” Washers [GGG],

[ZZ] [Figure 8].

TOOLS: DRILL; 1/4” & 13/16” BITS, 3/8” & 7/16” WRENCHES, HAMMER, CENTER PUNCH

GGG

[Figure 8]

CCC

STEP 16

Attach the loose ends of each Balance Cable 1/4-20 X 1.5 Bolts Washers

1/4-20 Nylock Nuts [ZZ]

hole in from the corner of the lid as shown. [Figure 9] (NOTE: Smaller .75” Washers

[XX] should be installed on the interior.)

[YY] to the AerFoil Cover [UU] with

[III], 1/4-20 X 1 Fender

[HHH], .75” Washers [XX], and

using the third

[Figure 9]

HHH

III

STEP 17

NOTE: This step will be easiest if

someone assists you.

EEE

IMPORTANT: Remove and reattach each bolt ONE AT A TIME before moving to the next bolt.

Join two AerFoil Bands [EEE] together with one Band Spring [FFF] at the ends with the smallest holes. [Figure 10] Repeat for the remaining two AerFoil Bands and Spring. Attach the Band/Spring assembly to the AerFoil Cover by bending the assembly around the top edge of the Aerfoil with the padded side of the straps placed against the Cover as shown. Start at one corner by removing one Joint Connector Bolt [BBB] and then rethreading the Bolt through the larger hole at the end of the AerFoil Band [EEE] and then into the carrier cover [Figure 11]. Repeat this step for the other side of the carrier with the remaining Band/Spring assembly.

BBB

[Figure 11]

7/16” WRENCHES

TOOL: 5/32” HEX WRENCH

[Figure 10]

FFF

EEE

BBB

REMOVE & REATTACH

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ONE YEAR LIMITED WARRANTY

We warrant this Let’s Go Aero brand product during the time the original retail purchaser owns

it. This warranty terminates if a purchaser transfers the product to any other person.

Let’s Go Aero warrants this product to be free from defect in material and workmanship for

one year (retain your sales receipt for your records). Any product or part thereof found to be

defective within that period will be replaced without charge provided that: (1) the product was

not misused; (2) no alterations or modiﬁcations were made; (3) its failure was not a result of

normal wear expected in the use of the product; (4) the product or part is delivered, freight

prepaid, to Let’s Go Aero.

Manufacturers only obligation shall be to replace such products or parts proved to be defective.

A Return Merchandise Authorization is required prior to return. Please contact Let’s Go Aero

toll-free, at 877-464-2376 or 719-630-3800, or via email to [email protected] to get an

RMA number.

No warranty is given for LGA products purchased outside of the United States and Canada.

To register your product, visit the Let’s Go Aero website at www.LetsGoAero.com

Technical Suppor t

For assistance with this product, please contact us:

Let’s Go Aero, Inc.

4474 Barnes Road

USA

Phone: 877-464-2376 or 719-630-3800

Email: [email protected]

To learn more about our products and stay informed about useful options for transporting all kinds of

gear with your carrier, be sure to visit our website: www.LetsGoAero.com

Patent Numbers 6,609,725; 6,945,550; 8,079,613; D717718; 8,858,141; Patents Pending

Patent and trademark protected.

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