SP0104B Safari Rack 144 Sprinter Van
Product Information: Safari Rack 144
The Safari Rack 144 is a product by Flatline Van Co that can be
attached to your vehicle. It is a cargo rack that can be used to
carry various items. The package includes six side rail weldments,
one front basket weldment, one 144 rear basket weldment, five 47.5
crossbars, eight 1.1875 bayonets, eight Sprinter Safari rail
mounts, three F45 mounting brackets, four floor section fan side
panels, two floor section fan covers, one floor section 2, one
floor section 4, one basket front floor section, and one floor
section 6. The estimated installation time is four hours, and
additional help is suggested for a few of the install steps. The
necessary tools required for installation are a 3/8 wrench, 5/32
Allen key, 7/16 wrench, and a 9/16 wrench.
Product Usage Instructions
- Before beginning the installation process, make sure to
properly assemble and secure all Flatline Van Co products to your
vehicle. Improper attachment could result in an automobile accident
and cause serious bodily injury or death to you or others
involved. - If you have no mechanical experience and are not thoroughly
familiar with the installation procedures, it is recommended to
have the product installed by a professional installer or other
qualified persons. - Slide half of the rail nuts into the passenger side factory
roof rail and half of them into the driver-side rail. If you are
installing a side ladder, grab the two rail nuts from your ladder
hardware pack and put those two in on the driver side. These can be
added later. - Begin assembling your side rails by grabbing the six side rail
weldments, eight bayonets, and eight rail mounts. Assemble them as
shown in Figure 1. Use quick clamps to assist alignment, as shown
in Detail D. Tighten the side rail weldments and bayonets, but
leave the rail mounts slightly loose to allow adjustment. Note that
the carriage bolts that attach the rail mounts can be mounted
facing upward or downward for a clean look.
Regularly inspect the products for wear and damage to ensure
everyone’s safety.
Installation Guide
PRODUCT IMAGE
FLATLINE VAN CO · [email protected] · 888-667-5576
Safari Rack 144
SP0104B
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. We always recommend you use a professional to install any aftermarket accessories to your vehicle. If you have no mechanical experience and are not thoroughly familiar with the installation procedures, you must have the
product installed by a professional installer or other qualified persons. The responsibility is yours and must be taken seriously for everyone’s safety.
thanks.
FLATLINE VAN CO · [email protected] · 888-667-5576
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THANK YOU!
ARE YOU EXCITED ABOUT YOUR NEW SAFARI RACK 144? HERE ARE A FEW THINGS TO DO BEFORE BEGINNING THE INSTALLATION PROCESS–
· PLEASE INSPECT THE PRODUCT TO ENSURE THERE WAS NO DAMAGE INCURRED DURING SHIPPING.
· IF THERE IS DAMAGE TO REPORT, PLEASE CONTACT OUR CUSTOMER SERVICE DEPARTMENT AS SOON AS POSSIBLE.
· NEXT, USING THE “PACKAGE CONTENTS” PAGE, CHECK INVENTORY AND FAMILIARIZE YOURSELF WITH THE PARTS AND HARDWARE.
· GATHER ALL TOOLS REQUIRED FOR INSTALL. -3/8 BOX WRENCH OR SOCKET -7/16 BOX WRENCH OR SOCKET -9/16 BOX WRENCH OR SOCKET -5/32 HEX KEY ALLEN WRENCH
ESTIMATED INSTALL TIME- 4 HRS ADDITIONAL HELP IS SUGGESTED FOR A FEW OF THE INSTALL STEPS.
TOOLS
3/8 WRENCH
5/32 ALLEN KEY
7/16 WRENCH
9/16 WRENCH
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PACKAGE CONTENTS
SIDE RAIL WELDMENT QTY – 6
FRONT BASKET WELDMENT QTY – 1
144 REAR BASKET WELDMENT QTY – 1
47.5″ CROSSBAR QTY – 5
1.1875 BAYONET QTY – 8
SPRINTER SAFARI RAIL MOUNT QTY – 8
F45 MOUNTING BRACKET QTY – 3
FLOOR SECTION FAN SIDE PANEL QTY – 4
FLOOR SECTION FAN COVER QTY – 2
FLOOR SECTION 2 QTY – 1
FLOOR SECTION 4 QTY – 1
BASKET FRONT FLOOR SECTION QTY – 1
FLOOR SECTION 6 QTY – 1
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HARDWARE
0.375-16 X 1 SQUARE NECK CARRIAGE BOLT
QTY – 22
3/8-16 X 0.75 FLANGED HEX HEAD SCREW
QTY – 8
1/4-20 X 0.75 FLANGED HEX HEAD SCREW
QTY – 28
1/4-20 X 0.75 FLANGED BUTTON HEAD HEX DRIVE SCREW
QTY – 38
3/8 SCREW FLAT WASHER QTY – 22
3/8 SCREW BELLEVILLE SPRING LOCK WASHER
QTY – 8
1/4-20 X 0.5 FLANGED BUTTON HEAD HEX DRIVE SCREW
QTY – 43
1/4 SCREW FLAT WASHER QTY – 8
3/8-16 NYLON INSERT LOCKNUT QTY – 22
SPRINTER RAIL NUT QTY – 8
1/4-20 ECONOMY T-NUT QTY – 43
1/4-20 NYLON INSERT LOCKNUT QTY – 14
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LET’S GET STARTED!
1.
SLIDE HALF OF THE RAIL NUTS INTO THE PASSENGER SIDE FACTORY ROOF
RAIL, AND HALF OF THEM INTO THE DRIVER SIDE RAIL.
NOTE- IF YOU’RE INSTALLING A SIDE LADDER, GRAB THE TWO RAIL
NUTS FROM YOUR LADDER HARDWARE PACK, AND PUT THOSE TWO
IN ON THE DRIVER SIDE. THESE CAN BE ADDED LATER, IT JUST
SAVES TIME TO DO IT NOW.
2.
NEXT, BEGIN ASSEMBLING YOUR SIDE RAILS. GRAB YOUR 6 SIDE RAIL
WELDMENTS, 8 BAYONETS, AND 8 RAIL MOUNTS. BEGIN ASSEMBLING THEM
AS SHOWN IN FIGURE 1. WE FIND THAT A GOOD SIZED TABLE OR
WORKBENCH MAKES THIS A BIT EASIER. TO ASSIST ALIGNMENT, IT’S
SUGGESTED TO USE SOME QUICK CLAMPS AS SHOWN IN DETAIL D (SEE
NEXT PAGE FOR DETAIL). TIGHTEN THE SIDE RAIL WELDMENTS AND
BAYONETS, BUT LEAVE THE RAIL MOUNTS SLIGHTLY LOOSE TO ALLOW
ADJUSTMENT.
NOTE- THE CARRIAGE BOLTS THAT ATTACH THE RAIL MOUNTS CAN
BE MOUNTED FACING UPWARD OR DOWNWARD FOR A CLEAN LOOK.
FIGURE 1
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DETAIL A
DETAIL B
DETAIL C
1/4-20 X 0.75 FLANGED BUTTON HEAD HEX DRIVE SCREW
1/4-20 X 0.75 FLANGED HEX HEAD SCREW
1/4 SCREW FLAT WASHER
1/4-20 NYLON INSERT LOCKNUT
0.375-16 X 1 SQUARE NECK CARRIAGE BOLT
3/8 SCREW FLAT WASHER
3/8-16 NYLON INSERT LOCKNUT
DETAIL D
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3.
AT THIS POINT, YOU SHOULD HAVE 2 COMPLETE SIDE RAIL ASSEMBLIES AS
SHOWN BELOW IN FIGURE 2. WITH THE HELP OF A SECOND PERSON, TAKE
THE SIDE RAIL ASSEMBLIES UP TO THE TOP OF THE VAN. LINE UP THE FRONT
RAIL MOUNT WITH THE VERY FRONT OF YOUR ROOF RAIL.
NOTE- LAY A BLANKET OR CARDBOARD DOWN ON THE ROOF OF
THE VAN BEFORE BRINGING THE SIDE RAILS UP IF YOU ARE
WORRIED ABOUT SCRATCHING THE PAINT.
4.
NOW LEAN THE RAIL ASSEMBLY UP AND ONTO THE ROOF RAIL AND THREAD
IN THE BOLTS TO THE RAIL NUTS. LEAVE THESE BOLTS LOOSE; WE’LL COME
BACK AND TIGHTEN THEM AT A LATER STEP.
FIGURE 2
3/8-16 X 0.75 FLANGED HEX HEAD SCREW
3/8 SCREW BELLEVILLE SPRING LOCK WASHER
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5.
WE RECOMMEND HAVING A SECOND SET OF HANDS TO HELP WITH THIS STEP
AS WELL. START WITH THE REAR BASKET (SHORTER, DOES NOT HAVE FVC
BADGE ON SIDE) AND SLIDE IT ONTO THE EXPOSED BAYONETS ON THE REAR
OF THE RACK. ATTACH USING THE SAME HARDWARE USED TO ASSEMBLE THE
SIDE RAILS, AND USE THE SAME CLAMPING METHOD AS BEFORE TO ENSURE
GOOD ALIGNMENT. REPEAT THE SAME STEPS FOR THE FRONT BASKET.
NOTE- REMEMBER TO LEAVE THE RAIL MOUNT FEET LOOSENED.
WE’LL TIGHTEN THOSE DOWN IN A LATER STEP.
FIGURE 3
BACK
FRONT
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6.
ONCE YOU’VE GOT BOTH ENDS TIGHTENED; IT’S TIME TO START LAYING
DOWN YOUR CROSSBARS. WE’VE PROVIDED DIMENSIONS BELOW IN
FIGURE 4 TO MAKE IT EASY. MAKE SURE YOU VERIFY THE DIMENSION ON
BOTH ENDS OF THE CROSSBAR RELATIVE TO THE REFERENCE POINT TO
ENSURE THEY ARE SQUARE. THIS WILL MAKE IT MUCH EASIER WHEN
MOUNTING YOUR DECKING PANELS LATER. THE DIMENSIONS ARE PULLED
FROM THE FLANGE ON THE TRAY OF THE REAR BASKET TO THE FRONT FACE
OF THE CROSSBAR (FURTHEST SIDE) WAIT TO TIGHTEN THE CROSSBARS
UNTIL YOU HAVE PUT ALL OF THEM IN.
NOTE- REMEMBER TO LEAVE THE RAIL MOUNT FEET LOOSENED.
WE’LL TIGHTEN THOSE DOWN IN A LATER STEP.
DETAIL E
1/4-20 X 0.75 FLANGED HEX HEAD SCREW
FIGURE 4
REFERENCE POINT
”
”
”
9 16
39196 ”
”
9 16
1 16
9 16
0
10
73
102
118
FRONT
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BACK
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1 2
”
AWNING MOUNTS
7.
THIS STEP IS ONLY NECESSARY IF YOU ARE MOUNTING A FIAMMA F45 (OR
SIMILAR) AWNING TO YOUR SAFARI RACK. IF YOU ARE NOT MOUNTING AN
AWNING, SKIP TO STEP 8.
YOU WILL MOUNT THE 3 AWNING BRACKETS TO THE UNDERSIDE OF THE
PASSENGER SIDE OF THE RACK AS SHOWN IN DETAIL F TO THE RIGHT. THE
LOCATIONS ARE SHOWN BELOW IN FIGURE 5 AND USE THE SAME
REFERENCE POINT AS THE CROSSBARS. THESE BRACKETS SHOULD BE
TIGHTENED ONCE ATTACHED TO THE RACK USING THE SAME HARDWARE SET
AS THE RAIL MOUNTS.
NOTE- THE DIMENSIONS GIVEN ARE SUGGESTED BASED ON OPTIMAL
SUPPORT LOCATIONS. THESE MAY DIFFER IF USING A SMALLER OR
LARGER AWNING THAN TYPICAL, AND ADDITIONAL MOUNT SLOTS
ARE AVAILABLE TO SUIT YOUR NEEDS.
THE AWNING BRACKETS HAVE SLOTS FOR MINOR ADJUSTMENT.
AWNING BRACKET
FIGURE 5
”
DETAIL F
REFERENCE POINT
1 2
18
55″
120
0
FRONT
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BACK
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8.
BEFORE MOVING ONTO THE FLOOR SECTIONS; NOW IS THE TIME TO CENTER
THE RACK ON YOUR VAN AND TIGHTEN THE RAIL MOUNTS, BOTH TO THE VAN,
AND TO THE RACK. ONCE YOU FINISH THAT; WE CAN PROCEED TO
ATTACHING THE FLOOR SECTIONS.
9.
START WITH THE REAR FLOOR SECTION FIRST AND WORK YOUR WAY UP.
IMPORTANT- THE FRONT AND REAR SECTIONS LOOK VERY SIMILAR. TO TELL
THEM APART; THE REAR SECTION WILL MEASURE ROUGHLY 12″ LONG, WHILE
THE FRONT MEASURES ROUGHLY 11.25″. INSERT THE HARDWARE INTO THE
SLOT ON THE CROSSBAR AS SHOWN IN DETAIL G TO THE RIGHT, THEN ALIGN
THEM USING YOUR ALLEN KEY AS SHOWN IN DETAIL H. DETAIL J SHOWS A
SECTION VIEW OF HOW THE FASTENERS ATTACH THE END FLOOR SECTIONS
TO THE TRAY OF THE BASKET WELDMENTS WHERE NO CROSSBARS ARE
PRESENT TO ATTACH TO. FIGURE 6 ON THE NEXT PAGE SHOWS PANEL
LOCATIONS.
ALIGNMENT IS KEY HERE TO ACHIEVE A HIGH QUALITY END RESULT, SO USE
YOUR EYES TO ALIGN THE PANELS STRAIGHT WITH THE CROSSBARS. THE
MOUNTING SLOTS HAVE A WIDE RANGE TO ACCOUNT FOR ANY
MISALIGNMENT THAT MAY HAVE OCCURRED DURING ASSEMBLY OF THE
RACK.
NOTE- WE RECOMMEND APPLYING BLUE LOCTITE (OR SIMILAR
THREADLOCKER) TO THE SCREWS THAT HOLD THE FLOOR SECTIONS
DOWN TO THE CROSSBARS TO ENSURE THEY DO NOT COME LOOSE
WHILE DRIVING. THIS IS NOT NECESSARY ON FRONT AND REAR BOLTS
WITH NYLOCK NUTS.
DETAIL H
DETAIL G DETAIL J
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· FLOOR SECTION 6 · FLOOR SECTION FAN SIDE PANEL · FLOOR SECTION FAN COVER · FLOOR SECTION 4 · FLOOR SECTION 2 · BASKET FRONT FLOOR SECTION
BACK
FRONT
REMOVABLE FOR MAXXAIR FAN
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10.
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. INSTALL IS NOW COMPLETE, AND YOU’RE READY FOR ADVENTURE!
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thanks!
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