Pickup Truck Rack. Installation instructions for Ford - Chevy - Ram

Transcription

1 Installation instructions for Pickup Truck Rack Ford - Chevy - Ram MyGlassTruck.com 200 Acorn Road LOCAL WEB Glassboro, NJ FAX Version 1.0 January 2018 MyGlassTruck.com is a Division of Demountable Concepts, Inc.

2 TABLE OF CONTENTS Section 1 Orientation and Required Tools Page 4 Section 2 Placing Rack on Bed of Vehicle Page 6 Section 3 Bolting Cross Bars to Rack Page 10 Section 4 Secure Rack to Bed Rail Page 12 Section 5 Underbody Mounts Page 13 Section 6 Install Front Stop Page 17 Section 7 Wiring Page 18 Section 8 Assemble Poles Page 22 Section 9 Optional Metal Carrier Installation Page 25 Section 10 Final Inspection Check List Page 31 Section 11 Activate Your Warranty Page 32 2

3 PLEASE READ THIS CAREFULLY Thank You for Choosing MyGlassTruck.com North America s Glass Rack Leader This document s purpose is to provide a qualified installer with the steps necessary to perform a safe and correct installation. Before beginning installation read this guide and all other instructions provided by MyGlassTruck.com, third party component providers and vehicle providers to ensure you are familiar with the installation procedure, rack and vehicle. If you have questions, please call MyGlassTruck.com at Our qualified personnel will gladly provide answers.! CAUTION Demountable Concepts, Inc., parent company of MyGlassTruck.com, has provided within this document detailed installation instructions for the installer of the aluminum truck rack provided by MyGlassTruck.com. Failure to follow these instructions or failure to follow safe shop and workplace practices could result in injury or death of the installer or end user of this equipment. PLEASE read this instruction manual thoroughly before beginning the installation process. If you do not understand any step or procedure that is outlined in the manual, immediately call the Demountable Concepts, Inc. engineering department at Hours of operation are 8 am to 5 pm EST, Monday through Friday. DO NOT PROCEED WITH ANY INSTALLATION PROCEDURE IF YOU ARE NOT CERTAIN OF ITS CONTENT, INTENTION AND DESCRIPTION.! IMPORTANT When installed, this glass rack and any other components must not alter or prevent vehicle compliance to existing state or federal standards. The finished rack and vehicle should comply with all vehicle manufacturer guidelines.! DO THIS BEFORE YOU START Before beginning installation, please review this manual and locate each hardware bag and component of your rack. If anything is missing or you have questions please call We will be happy to assist you. 3

4 SECTION 1 Orientation and Required Tools WHAT'S INCLUDED IN YOUR CRATE Before starting to install your glass rack, please locate all your parts and hardware. Here is a list of everything that is included in your crate: Standard Drivers Side Glass Rack Passengers Side Glass Rack Crossbar with Cluster Lights Additional Aluminum Crossbars (2) Hardware Kit - Crossbars Hardware Kit - Bedpans Loose Slat Hardware Kit - Slat Vertical Rubber Under Mounts (4) Wiring Kit Exhaust Deflector Hardware Kit - Exhaust Deflector Adjust-A-Poles (6) Hardware and Cleats for Adjust-A-Poles Optional Loose Post Hardware Kit - Loose Post Extra Adjust-A-Poles Over-the-Cab Metal Carrier Any Additional Options 4

5 SECTION 1 Orientation and Required Tools BECOME FAMILIAR WITH YOUR GLASS RACK! REQUIRED TOOLS: Impact wrench, 21/64" Drill Bit, 1/2" Socket, 3/8" Drill Bit, 9/16" Socket, Vise Grip style clamps. 5

6 SECTION 2 Installing Rack on Bed of Vehicle STEP 1: PREPARING DRIVER SIDE Locate the front of the rack, indentified by the holes where the front body stop will be. Note: This is the location of the front stop to help distinguish the driver side vs. the passenger side Place the rack up on the bed rail. Use clamps to hold the rack in place to the top of the bed rail. Use jack stands or wooden blocking to support the rack. Make sure the carrier does not interfere with any doors or fuel openings.! INSTRUCTIONS CONTINUE ON THE FOLLOWING PAGE. 6

7 SECTION 2 Installing Rack on Bed of Vehicle STEP 2: NON-ATTACHED HORIZONTAL SLAT The location of the fuel door on the pickup in relation to the glass rack will vary depending on the pickup model and the chosen height for the bedpans. The slat that is likely to cover the fuel door is left loose so that it can be installed after the rack is mounted to avoid blocking the fuel door. Hardware Kit V-4 is included to bolt on this slat. Leave this slat loose until the rack has been mounted properly Find a good spot either above or below your fuel door to place the horizontal slat. Clamp the slat in place and drill 1/4" holes at the intersections. Using 1" x 1/4" bolts, washers, and nuts, secure the horizontal slat back to the glass rack. We also provide vertical rubber to be placed into the posts once the slat is in place. Vertical rubber will need to be cut to size. 7

8 SECTION 2 Installing Rack on Bed of Vehicle STEP 3: POST FOR FUEL DOOR On certain vehicles, the second post may also block the fuel door. While sliding the rack forward or back on the bed rail may solve this, occasionally another solution will be needed. We have found that Ford F-150's, all Dodge pickups, and all Toyota pickups may need this solution. A 45" piece of post is provided in case one of the vertical posts fall over the fuel door. Cut the post out to expose and access the fuel door. Use the provided post and hardware to strengthen the rack by placing it to the right or the left of the fuel door. Use the provided 1" x 1/4" bolts, washers, and nuts. (V-4 Hardware Kit) Attach horizontal slat first, then cut away vertical post with a reciprocating saw in these locations Insert 45" post material behind slats and clamp in place Drill 1/4" holes and bolt post into place 8

9 SECTION 2 Installing Rack on Bed of Vehicle STEP 4: PREPARING PASSENGER SIDE Place the other rack on the passenger-side. Use clamps to hold in place on top of the bed rail. Use jack stands or wooden blocking to support the rack. Again, be sure your supports are strong enough to support the weight of the rack. Use clamps to hold rack to bed rail. When clamping the passenger-side rack onto the truck frame, maintain 61-1/2" between the aluminum bed pans and hold this number all the way back to the tailgate to keep the rack parallel. To ensure the racks are parallel, be sure to maintain 61-1/2" between the aluminum bed pans. 9

10 SECTION 3 Bolting Cross Bars to Rack STEP 1: BOLTING CROSS BARS Bolt the top cross bars into place at the front, middle, and rear of the glass rack. Make sure you bolt the cross bar that holds the triple cluster lights at the FRONT of the glass rack. (Using P-2 Hardware Kit) 5 FPO for new image The three amber lights should be facing forward, and the three red lights should be facing the rear. The wire for the lights should come out the driver's side. View from underside bracket, showing two bolts per side 10

11 SECTION 3 Bolting Cross Bars to Rack STEP 2: SETTING PITCH OF GLASS RACK Set the angle of the carrier by moving the bottom in or out. Be sure to keep the rack as close to the truck as possible. If the rack is touching the truck, be sure to use a rubber or foam pad between the truck and the rack. Try to keep about 1/2" between the rack and the truck. A proper angle is 5-6 degrees. Do not exceed the legal width limit of 102". Note: Be aware that the fenders of the truck bed may flare out and impede the rack! REMEMBER THE RACK AND VEHICLE MUST NOT EXCEED THE LEGAL OVERALL WIDTH OF 102" Tip: Download an app for your smartphone to quickly check the recommended five degree angle. 11

12 SECTION 4 Secure Rack to Bed Rail STEP 1: LOCATE PARTS AND HARDWARE P-3 Hardware Bag for Bed Rail ITEM SIZE QTY Hex Cap Screw Stainless 3/8" x 1-1/2" 8 USS Flat Washer Stainless 3/8" 8 Nylon Insert Locknut Plated 3/8" 8 Fender Washer Stainless 3/8" 16 STEP 2: SECURING ALUMINUM BED PAN TO VEHICLE BED RAIL Drill 4 holes through each rack and through the bed rail. Secure with 1-1/2" x 3/8" bolts, fender washers, washers, and lock nuts. Double check one more time that the bed pans are still 61-1/2" apart from each other all the way down the sides. Drill four (4) holes through aluminum bed pan and vehicle bed rail 12

13 SECTION 5 Install Underbody Mounts & Attach Bottom of Rack STEP 1: REVIEW PARTS AND HARDWARE Before beginning this portion of your installation locate and review all parts and hardware bags. Please call if anything is missing or you have questions. UNDERBODY MOUNTS PARTS A. Horizontal Undermount Arm (4) B. Vertical Undermount Bracket (4) C. "Boomerang" Support Arm (4) D. Rubber Shims (4) E. 4"x4" Aluminum Plates (4) P-1 Hardware Kit (not shown) E C B D A 13

14 SECTION 5 Install Underbody Mounts & Attach Bottom of Rack STEP 2: PRE-ASSEMBLE MOUNTING BRACKETS: Your crate contains two underbody mounts for single-sided rack configurations or four underbody mounts for double-sided rack configurations. Assemble the vertical vehicle attachment post, horizontal rack support and boomerang support brace using 3/8" x 1" bolts and locknuts. Will attach to rack ledge Will attach to truck chassis frame STEP 3: PLACEMENT OF UNDERBODY MOUNTS The shorter vertical post of the underbody mounts attaches to the truck's chassis frame and the longer horizontal rack support extends beyond the truck's outer wall to underneath the rack s ledge. Be sure not to interfere with any components on the truck chassis when attaching the underbody mounts. The approximate location of each underbody mount is: A. FRONT As close to the front edge of the rack as possible B. REAR Behind the rear wheels, outside of the leaf springs. A B 14

15 SECTION 5 Install Underbody Mounts & Attach Bottom of Rack If your rack sits high on the truck it may be necessary to cut off the top portion of the vehicle attachment post so the horizontal rack support is closer to the rack s ledge. Locate the underbody mounts on the chassis so the horizontal rack support meets the underside of the glass rack s ledge. Be sure the horizontal rack support is as close as possible to the glass rack s bottom ledge. STEP 4: ATTACH MOUNTS TO VEHICLE! NOTE: For 3/8" selftapping bolts use a 21/64" drill bit to drill pilot hole. BE VERY CAREFUL NOT TO DRILL THROUGH THE FUEL TANK! Using self-tapping 3/8" x 1-1/2" bolts with lock washers, bolt the mounting brackets to the truck's frame. Be sure the long arm of the bracket extends under the glass rack s bottom ledge. Sometimes at the rear underbody mount you can through-bolt with two 1-1/2" x 3/8" bolts, washers and lock-nuts. Once the underbody mounts are installed secure all bolts. Some Chevy models can use 4" bolts to secure the rear underbody mount to the chassis/frame. Be sure to use a minimum of two bolts per bracket through the chassis frame. Place one bolt high and one bolt low on the truck's frame. Do not interfere with brake lines, fuel tanks, fuel hoses, etc. You can vary the location of the boomerang shaped supports to work around cables and other obstacles 15

16 SECTION 5 Install Underbody Mounts & Attach Bottom of Rack STEP 6: ATTACH RACK TO MOUNTS Place the 4" x 4" aluminum wear plate between top of the underbody mount and underside of the ledge. Trim the plate as needed, then add rubber shims to fill the space. 4" x 4" aluminum wear plate Rubber shim Drill 3/8" holes through the ledge and top flange of each mounting bracket s horizontal rack support. Avoid drilling where rubber ledge blocks are located on ledge. Secure using 3/8" x 1-1/2" bolts, washers and nuts.! DOUBLE-CHECK THAT ALL NUTS AND BOLTS ARE TIGHTENED 16

17 SECTION 6 Install Front Stop STEP 1: LOCATE PARTS AND HARDWARE ITEM QTY Front Stops 2 V-6 Hardware Bags 2 STEP 2: INSTALL FRONT STOP The glass rack front stop is shipped detached from the rack. To attach, bolt the stop directly to the front of the glass rack through the pre-drilled holes using the 1/4-20" x 2-1/2" bolts provided. 17

18 SECTION 7 Wiring STEP 1: TOP CROSS BAR WIRING Bolt forward crossbar so that amber lights are facing forward and red lights are facing the rear of the vehicle. The wire should be on the drivers side of the glass rack. Drill a 1/2" hole on the forward most post of the glass rack and fish the black wire down the post to the lower corner of the glass rack. Protect the wire where it exits the glass rack with the provided black wire loom. Plug the male end of the crossbar wire into the double connector on a 14' Wire harness. Be sure to plug into the black wire. The crossbar wires are grounded into the crossbar. 18

19 SECTION 7 Wiring STEP 2: DRIVER'S SIDE WIRING Install FRONT amber light into the 14' harness by plugging in black to black and white to white. Run this harness to the rear of the vehicle, either OVER the wheel well or back along the frame. Be sure the wire does not interfere with any moving parts. Secure with wire ties. Run the 14' wire to the rear drivers side corner, near the red corner LED light. Plug the male end of the 14' and the Red LED connectors into a 72" wire harness. Run the 72" wire back along the rear undermount to the center of the vehicle near the bumper. Secure all the wires with wire ties or wire clips. 19

20 SECTION 7 Wiring STEP 3: PASSENGERS SIDE WIRING Install FRONT amber light into the 14' harness by plugging in black to black and white to white. Run this harness to the rear of the vehicle, either OVER the wheel well or back along the frame. Be sure the wire does not interfere with any moving parts. Secure with wire ties. Run the 14' wire to the rear passenger's side corner, near the red corner LED light. Plug the male end of the 14' and the Red LED connectors into a 72" wire harness. Run the 72" wire back along the rear undermount to the center of the vehicle near the bumper. Secure all the wires with wire ties or wire clips. STEP 4: FINAL CONNECTION Behind the bumper, locate wires that go to the 7 way trailer plug in the bumper. This is where you tap into the trucks power. Find an easily accessible section and remove any loom or tape to exposure individual wires. We have supplied blue weatherproof scotch locks. following scotch lock instructions, connect the brown wire to the factory brown (marker lights) and the white wire to the white wire (ground). Test that your lights turn on and off with the headlights. Retape the wires and secure any loose wire. Tip: Turn on truck headlights and be sure everything works!! LED LIGHTS ARE POLARITY SENSITIVE. THIS MEANS THAT IF THE BLACKS AND WHITES GET MIXED UP THE LIGHTS WILL NOT WORK. 20

21 SECTION 7 Wiring REFERENCE DIAGRAM Use this diagram to help identify different points on your glass racks to run your wire. Please make sure to protect all exposed wire with provided wire loom. 21

22 SECTION 8 Installing Your Exhaust Deflector EXHAUST DEFLECTOR DIAGRAM On some model pickup trucks hot exhaust is discharged directly onto wires. To avoid damage, use the exhaust deflector provided with this rack. Provided in your P-10 Hardware Kit, you will find three (3) 3/4" self-tapping screws that can secure this deflector onto your exhaust pipe. (If welding is an option, this deflector can be welded onto the exhaust pipe.) Exhaust Deflector 22

23 SECTION 8 Assemble Poles STEP 1: LOCATE PARTS AND HARDWARE Standard 5-Cleat Poles ITEM QTY Poles with Bolt-on Hook and Tab 6 Rubber Cleats 30 V-5 Hardware Bag for Pole Assembly X2 ITEM QTY Nylock Nut 15 Plastic Wing Nut 15 Stainless Steel Flat Washer 15 Black Rubber Glide Washer 15 Small Nylon Washer 15 Stainless Steel Bolt 15! IF YOU PURCHASED ADDITIONAL POLES YOU WILL RECEIVE ADDITIONAL HARDWARE 23

24 SECTION 8 Assemble Poles STEP 1: ASSEMBLE POLES Slide the head of a stainless steel bolt down the pole s channel. Assemble hardware and cleat as shown. Slide three cleats onto one side of the pole and two onto the other side. 24

25 SECTION 9 Optional Metal Carrier Installation STEP 1: REVIEW PARTS AND HARDWARE Before beginning this portion of your installation locate and review all parts and hardware bags. Please call if anything is missing or you have questions. METAL CARRIER PARTS A. 60" Metal Carrier B. 59.5" Angle Slats (2) C. Metal Carrier Hardware Bag D. V-11 Hardware Bag E. Brackets for Rear Crossbar (2) (Note: Brackets are different, one for right side and one for left side) F. 75" Rear Crossbar! REQUIRED TOOLS: Drill with 5/16" and 3/8" drill bits, 9/16" and 1/2" wrenches and sockets, clamps, and safety glasses. PLEASE NOTE: The forward crossbar has two mounting flanges attached to it. 25

26 SECTION 9 Optional Metal Carrier Installation STEP 2: ORIENTATION Position roof rack so that it clears the roof of the cab. Be careful not to have it too close to the roof since sometimes this will cause vibration and noise on the roof from restricted air flow. Three inch (3") clearance should be sufficient. Make sure carrier is at the same height on each side of the rack. Minimum of 3" of clearance between rack and roof. 26

27 SECTION 9 Optional Metal Carrier Installation STEP 3: SECURE CARRIER TO RACK Drill through roof rack with 3/8" drill bit. Drill all the way through horizontal piece of the metal carrier and the front post of the glass rack. Secure metal carrier with 4" x 3/8" bolt, washers and locknuts. Tighten securely. Note: Depending on your vehicle, you may have to trim any excess material on the horizontal extrusion. Secure with 4" x 3/8" bolt, washers and locknuts. 27

28 SECTION 9 Optional Metal Carrier Installation STEP 4: SQUARE UP METAL CARRIER Square up metal carrier with the main rack, then locate 1-1/2" aluminum angles show. Position top of support angle as shown here. Make sure that the welded flanges on the crossbar are positioned the right way around. Temporarily clamp angle to crossbar and metal carrier Close-up of clamp placement 28

29 SECTION 9 Optional Metal Carrier Installation STEP 5: DRILL OUT SUPPORT ANGLE Drill out support angle where it meets upper section of glass rack top support as shown with 3/8" drill. Drill out support angle where it meets lower section of roof rack as shown with 3/8" drill. Lower section Upper section Use 3/8" x 1" bolts to secure support angles to metal carrier and glass rack. Be sure to tighten all bolts securely. 29

30 SECTION 9 Optional Metal Carrier Installation STEP 6: INSTALL REAR CROSSBAR Clamp rear bar bracket in place on rear post. Please note that there is a left and right bracket to match the pitch of the racks. Be sure this bar is at the same elevation as the front metal carrier and level from side to side. Drill two 5/16" holes as shown per bracket. Secure bracket with 5/16" x 2 1/4" bolts. Place Crossbar into mounting brackets. Drill a 3/8" hole through the brackets and crossbar. Secure with locking pins. Note: Be sure to secure with locking pins! 30

31 SECTION 10 Final Inspection Check List CHECK FOR YES Roof rack is attached to van properly and all bolts are tight (roof rack mount) All bolts are tight where glass rack attaches to roof rack (roof rack mount) All bolts are tight where glass rack attaches to van body (bolt-through mount) All underbody mounts are installed properly and tight All bolts securing rack ledge to underbody mounts are tight Wheel skirt is bolted on properly Front stop is securely bolted in place Cleats are attached properly to all poles 31

32 SECTION 11 Activate Your Warranty Complete and return this form within 15 days to activate your warranty. Please print clearly using block letters. Return by mail or fax: MyGlassTruck.com FAX: Acorn Road Glassboro, NJ Rack purchased by: First and last names: Street address: City, State and zip code: Telephone: Installation Date: Rack installed by: (If different than purchaser) First and last names: Street address: City, State and zip code: Telephone: MyGlassTruck.com is always looking for ways to improve. Please write any comments about our glass racks or these installation instructions here: 32