WEATHER GUARD 210-3 User Manual

Driver Side Rear/ Passenger Side Front Rail

10-24 Nylon Lock Nut

Driver Side Front/ Passenger Side Rear Rail

Crossmember with Wear Strip

7/32" Hole

5/16-18 x 2-1/4" Carriage Bolt

3/8-16 x 3/4" Thrd. Cut Bolt

Stand

5/16-18 x 3/4" Carriage Bolt

Center Stand

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

INSET

5/16-18 x 3/4" Carriage Bolt

Cushion Strip 5/16-18 x 1-1/4"

Clamp

Center Stand Adjusting Plate

Rail Support

5/16" Flat Washer

5/16-18 Nylon Lock Nut

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

ASSEMBLY INSTRUCTIONS

1. Assemble the Rail Halves. Be sure to include Cushion Pad between the halves.

2. Note: Gutter widths on the Chevy GMT-600/GMC Savana vans are narrower. If installing

this rack on one of these vans, 3-1/2" will need to be cut off of each crossmember.

10-24 x 2-3/4" Flat Hd. Screw

Tie Down

3/8-16 Nylon Lock Nut

3/8" Flat Washer

Cushion Strip

Figure 3. Placement Dimensions

3/8-16 x 1-1/4" Carriage Bolt

Ladder Strap

1/4-14 x 3/4 Self Drilling Screw

1/16" Hole

Measure this distance. If greater than 5/8" a Spacer is required.

Figure 2. Safari Rack Assembly

Rail

Carriage Bolt

Support

5/16-18 x 1-1/2" Carriage Bolt

4. Insert the Crossmembers into the sockets on one rail assembly. Be sure the Air Foil faces forward.

5. Slide the other rail assembly onto the Crossmembers with the Crossmembers fully into the sockets.

NOTE: The Ford Econoline and GMT-600/GMC Savana vans have an upward bow in the center of the gutter. When installing the rack, we suggest using the dimensions shown in Fig- ure 3. All measurements are from center to center of the stands. The van rack placement on the roof can vary somewhat, but the dimensions (shown in Fig. 3.)must be held.

9. With the help of others, place the rack on the vehicle. Make sure the mounting Stands are all resting in the gutter. Adjust the Stands so both sides match each other.

NOTE: STEPS 10-13 ARE FOR GM VAN INSTALLATION ONLY. IF YOU ARE NOT INSTALLING RACK ON A GM VAN, SKIP TO STEP 14.

10. Due to excess body caulk in some gutters on GM vans, it may be necessary to place a

1/4" thick spacer in between the Stand and the Clamp. The stand must contact the Van roof gutter as shown in Figure 4.

11. Using a ruler or tape measure, measure the distance from the Stand to the outer edge of the gutter (See Figure 4). If this dimension is greater than 5/8" of an inch, a 1/4" Spacer will need to be installed. In extreme cases, a portion of the caulk might have to be cut out of the gutter and then re-caulked after the rack is installed.

12. If a spacer is not required, (dimension measured is 5/8" or less) skip step 13 and install the Clamps as shown in Figure 2.

13. If a 1/4" Spacer is required, install the Spacer between the Stand and the Clamp as shown in Figure 5.

14. Fasten the Stand Clamps to hold stands to the gutter (see Figure 2.). Tighten all nuts.

Air Foil

Gutter

Caulk

Figure 4. Measure caulk thickness

Tighten the vertical bolt so the Clamp is drawn up firmly under the rain gutter. Tighten the horizontal bolt. Recheck all rack bolts to be sure they are tight. At the end of the first week of use, check all fasteners for proper tightness and then every three months thereafter.

Stand

GM Van Roof

5/16-18 x 1-1/2" Carriage Bolt

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

1/4" Thk. Spacer

5/16-18 x 1-1/4" Carriage Bolt

Figure 5. Install 1/4" Spacer between Stand and Clamp if dimension measured is greater than 5/8"

GM Van Roof

3. On a Crossmember, attach the Air Foil. Center the Air Foil on the Crossmember, mark each hole location, drill the marks with a 1/16" drill bit, then fasten.

NOTE: If using a drill driver, it is unnecessary to drill the holes for the self-drilling screws.

CAUTION

To keep debris out of your eyes when drilling, wear protective eyewear.

6. Assemble the Front and Rear Stands. Loosely fasten the Front and Rear Mounting Stands

to the side rail assemblies, as the Stands will have to be adjusted on the vehicle.

7. If installing the rack on a Ford Econoline or a GMT-600/GMC Savana van, (see Figure 2 Inset) the Center Stand will be bolted to the Center Stand Adjusting Plate through the bottom

holes [B], to compensate for the upward bow in the center of the gutter. Secure. If installing the rack on Chrysler or older Ford or GM vans, the top holes [A] will be used. Attach the center stand assembly to the rails.

8. Cut Cushion Strip into 8" lengths and press onto the underside of the six Stands where the Stand will rest in the gutter.

WARNING

Ladders must be secured per ANSI standard A142.2-1990 paragraph

8.4.4. Ladder damage will occur from road shock and vehicle vibration if the ladder is not properly secured to the ladder rack. Bouncing and side to side motion of a improperly secured ladder will cause wear and weaken the ladder. Using a damaged ladder could lead to a structural collapse and could result in a serious injury or death.

Part No. 24-0220 REV. B ECN 5315 05/13