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INSTALLATION MANUAL
Model 225-3 Accessory Center Crossmember
VAN STORAGE SOLUTIONS
FOR THE WAY YOU WORK™
ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS
BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.
WARNING
This product is only intended for, and only designed for, transporting ladders, lumber, pipe and other similar materials. It is the
responsibility of the user to secure these materials to the rack be fore transporting. Any modications made to this product, or use of
this product for any other purpose than its intended use, could create a hazardous condition that can cause serious personal injury
or property damage. Failure to comply could result in death or serious body injury.
CAUTION
To keep debris out of your eyes always wear protective eye wear. Do not apply too much pressure when drilling. Too much pressure
may cause dimples in the roof around the holes. Also, there may be a danger of penetrating the interior head liner. Failure to heed
this warning will result in death or serious injury.
– NOTICE –
for Models 223-3 & 224-3
WWW.WEATHERGUARD.COM
Any modication or unintended use of this product shall immediately void all manufacturers warranties. Manufacturer disclaims all
liability for injuries to persons or property resulting from any modication to, or unintended use of this product.
INSTALLATION TIME
Approximate installation time: 30 minutes per unit (0.5 hours) depending on van equipment installation experience.
TOOLS REQUIRED
• Electric Drill
• 9/32 & &13/32" Drill Bits
• Straight board (long enough to span
the Crossmembers of your rack)
• Ratchet Wrench
• 1/2" Socket (deep well preferred)
• 7/16" Socket
• 3/8" Socket
• 3" Socket Extension
• 7/16 & Open or Box End Wrench
• 9/16 & Open or Box End Wrench
• Ruler
• 1- Crossmember
• 2- Mounting Bracket
• 2- Mounting Pad
• 2- Clamp Bar
• 2- 221 Stand
PARTS LIST
BOLT KITS
Bolt Kit #32-0016 is provided with the 225-3. Check this bolt kit to be sure the following parts are included:
DESCRIPTION
Installation Tool
1/4-20 Blind Fastener
QTY.
1
4
DESCRIPTION
1/4" Flat Washer (yellow)
1/4-20 x 1-1/2" Hex Hd. Bolt
QTY.
1
4
*24-0165*
1/4-20 x 2-1/4" Blk. Ox. Bolt
5/16-18 Nylon Lock Nut
1/4" Lock Washer
1/4" Flat Washer
1
6
6
8
1
5/16-18 x 7/8" Carriage Bolt
1 oz. Tube E-6000 Sealant
Spacer - 1/8" thick
1/4-20 Nylon Lock Nut
Part No. 24-0165 Rev B 10/11 (ECN 5026)
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4
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INSTALLATION INSTRUCTIONS
Figure 1. Parts Identification
221-3 Stand
221-3 Center
Mounting Bracket
NOTE: This instruction sheet is designed for vehicles with the van rack already installed. If installing the 225-3 while
installing a 223-3 or 224-3, follow those instructions, which will refer you back to this instruction sheet when necessary.
221-3 Stand
STEP 1. Remove the two #10-24 Screws that hold the front and rear side rails together. Unbolt and remove both front
rails from the front Crossmember. Unbolt the Adjustable Ladder Clamp and corresponding Ladder Sway Brace from
the front Crossmember if you plan on moving them to the 225-3 Crossmember.
STEP 2. Fasten the Mounting Brackets to the Stands just loose enough so the Mounting Brackets will pivot on the
bolts (see Figure 2.).
221-3 Center
Mounting Bracket
*NOTE: If installing the rack on a
Windstar van, use the 5/16-18 x 1-1/4"
Carriage bolt (removed from the front
Crossmember/Stand) in place of the
5/16-18 x 7/8" Carriage Bolt if
fastening the Stand and an Adjustable
Clamp Assembly to the Crossmember.
Use a 5/16- 18 x 7/8" carriage bolt
from the 225-3 bolt kit to replace the
5/16-18 x 1-1/4' carriage bolt used for
the 225-3.
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STEP 3. Loosely fasten the Stands to the Crossmembers.
Figure 1. Parts Identification
Figure 2. Stand Assembly
221-3 Stand
221-3 Center
Mounting Bracket
STEP 4. Adjust then tighten the Stand Assemblies to the following dimensions:
Chevy Astro/GMC Safari: "A" - 1-1/16" Ford Windstar: "A" - 7-5/8"
"B" - 56-7/8" "B" - 43-3/4"
Dimension "A" should center the Stands side to side.
Adjust both Stands accordingly if they are not even.
STEP 5. (Only if relocating the Ladder Guide and Adjustable Clamp Assembly) Place a ladder in position on the 2253 Crossmember, on a side with an Adjustable Clamp. Place a Ladder Guide in the Crossmember slot, 1/2" from the
ladder side. Fasten the Ladder Guide. Repeat this for the other side of the 225-3 if applicable. If you will be carrying a
step ladder, you may want to wait until the rack is completely installed before mounting the Ladder Guide(s), to ensure
proper Ladder Guide location due to the taper of the ladder sides.
STEP 6. Slide the 225-3 Crossmember Assembly onto the rear side rails. Refasten the front side rails to the rear side
rails and front Crossmember.
STEP 7. Move the 225-3 Crossmember to the dimension shown in Figure 4. Mark through the obrounds in the
Mounting Brackets at the point where the Mounting Bracket radius meets the roof. Move the rack rearward so the
marks are accessible.
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Step 8 for Astro / Safari
STEP 8. Drill the marks with a 13/32"
bit. Apply E-6000 Sealant to the
roof around each hole. Install Blind
Fastener following the installation
instructions on the back page. Once
installed, ll the top of the Blind
Fastener holes with E-6000 Sealant.
Fasten the rack as shown in Figure 5.
Step 8 for Ford Windstar
STEP 8. Drill the marks with a 9/32"
drill bit. Apply E-6000 Sealant to the
roof around each hole. Fasten the
Rack to the roof as shown in Figure
6.
STEP 9. Place the straight board across the Crossmembers on one side of the rack. Raise the 225-3 Crossmember
up to the board, then tighten the Mounting Bracket to Stand bolts on that side. Repeat this for the other side of the
rack.
STEP 10. To adjust the Adjustable Clamp(s), loosen the Adjustable Clamp(s) bolts. Open the Rear Clamp, and place a
ladder on the rack. Close the Rear Clamp. Adjust the Adjustable Clamp forward or back to capture the nearest ladder
rung. Tighten the bolts.
INSTALLATION INSTRUCTIONS USING BLIND FASTENERS
STEP 1. Place a drop of oil on the black oxide bolt before assembling.
STEP 2. Place the Blind Fastener in the hole and use a 7/16" wrench to tighten black
7/16” Wrench
(Or 7/16” Socket)
Black Oxide Bolt
Flat Washer
9/16” Wrench
Installation Tool
Blind Fastener
hex bolt until the blind fastener is fully seated.
NOTE: When setting black hex bolt, it will start out hard. As the Blind Fastener
"bulbs" out it will get easier, until it bottoms out or sets. Make sure the Blind
Fastener and Installation Tool do not turn during installation.
WEATHER GUARD® PRODUCT REFINISHING PROCEDURES
All WEATHER GUARD® products are nished with a polyester powder coating, and
it is important to follow these procedures to get proper adhesion. As Knaack LLC
cannot control the nishing of the products, the warranty for WEATHER GUARD®
Products on paint is not applicable on renished products.
STEP 1. Sand the surface to be painted with 180-200 grit sand paper to rough up the
surface. This should be followed by wet sanding with a 400 grit wet or dry paper.
STEP 2. Wipe down the sanded surface with ketone based thinner. This removes the
dust and softens the powder coating for better paint adhesion.
STEP 3. Wipe sanded area with a tack rag to remove loose dust and particles before
painting.
NOTE: Do not use a lacquer over the powdered coating.
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KNAACK LLC LIMITED LIFETIME WARRANTY FOR WEATHER GUARD® PRODUCTS
WEATHER GUARD® Products — Limited Lifetime Warranty
(Purchased on or after 1/1/2009)
Knaack, LLC (the “Manufacturer”) warrants to the original purchaser only that WEATHER GUARD® Truck and Van Products
(the “WEATHER GUARD® Product”) will be free from defects in material and workmanship from the date of purchase and
continuing for the expected lifetime of the WEATHER GUARD® Product. A copy of the original sales receipt must be supplied
to the Manufacturer at the time a warranty claim is made. This warranty terminates if the original purchaser transfers the
WEATHER GUARD® Product to any other person.
What is Covered
All WEATHER GUARD® Products identified above that are purchased on or after January 1, 2009.
What We Will Do to Correct Problems
Subject to the limitations and exclusions described in this limited warranty, the Manufacturer will remedy defects in materials
or workmanship by providing one of the following remedies at its option and without charge to the original purchaser for parts
or labor: (a) repairing the defective portion of the WEATHER GUARD® Product or (b) replacing the entire WEATHER GUARD®
Product. In addition, the manufacturer may elect at its option, not to repair or replace the WEATHER GUARD® Product, but
rather issue to the original purchaser a refund equal to the purchase price paid for the WEATHER GUARD® Product or a credit
to be used toward the purchase of new WEATHER GUARD® Product.
What is Not Covered
This limited warranty expressly excludes:
• Defects caused by normal wear and tear, cosmetic rust, scratches, accidents, unlawful vehicle operation, or
modification to the product, or any types or repair of a WEATHER GUARD® Product other than those authorized or
provided by the Manufacturer.
• Defects resulting from conditions beyond the Manufacturer’s control including, but not limited to misuse, overloading,
or failure to assemble, mount or use the WEATHER GUARD® Product in accordance with the Manufacturer’s written
instructions or guidelines included with the WEATHER GUARD® Product or made available to the original purchaser.
• Damage to the contents of the box or vehicle.
• TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL THE MANUFACTURER BE LIABLE FOR ANY
INCIDENTAL, SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, INCLUDING ANY ECONOMIC LOSS,
WHETHER RESULTING FROM NONPERFORMANCE, USE, MISUSE OR INABILITY TO USE THE WEATHER
GUARD® PRODUCT OR THE MANUFACTURER’S NEGLIGENCE.
No Other Express Warranty Applies
This Limited Lifetime Warranty is the sole and exclusive warranty for WEATHER GUARD® products. No employee, agent,
dealer, or other person is authorized to alter this warranty or make any other warranty on behalf of Knaack LLC.
Notification Procedures
If the WEATHER GUARD® Product does not conform with the terms of this limited warranty, the original owner must promptly
notify the Manufacturer in writing upon discovery of the nonconformity. In order to receive the remedies under this limited
warranty, the warranty claim must describe the nature of the nonconformity, and a copy of the original sales receipt, invoice,
bill or other proof of purchase must accompany the claim. Repairs or modifications made to the WEATHER GUARD® Product
by other than the Manufacturer or its authorized agent will nullify this limited warranty. Coverage under this limited warranty is
conditioned at all times upon the owner’s compliance with these required notification and repair procedures. Warranty claims
must include reciprocal contact information and may be made via certified mail to:
Knaack LLC
ATTN: Warranty Claims
420 E. Terra Cotta Avenue
Crystal Lake, IL 60014
*24-0165*
If you have any questions, please call toll free at 1-800-456-7865.
©2011 Knaack LLC
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Part No. 24-0165 Rev B 10/11 (ECN 5026)
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