Fvco Pm0102b Low Pro Roof Rack 159 Hr Installation Guide (+ PDF)

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PM0102B Low Pro Roof Rack 159 HR

Product Information

The Low Pro Roof Rack 159 HR is a product manufactured by
Flatline Van Co. The product comes with a set of driver and
passenger front and rear rails, crossbars, rail connecting
brackets, fairing brackets, anchor stud brackets, clamping foot
brackets, fairing gasket, fairing, hardware pack, and sticker pack.
The product is designed to be installed on top of a vehicle’s roof
and must be properly assembled and secured before attaching to the
vehicle. The product is intended for use as an aftermarket
accessory and should be installed by a professional installer or
other qualified persons if the user has no mechanical experience or
is not thoroughly familiar with the installation procedures.

Product Usage Instructions

Before beginning the installation process, ensure that you have
the necessary tools which include a 7/16 wrench, 1/2 wrench, and
5/32 Allen key.
Check that all the package contents are available and accounted
for.
Start by placing the anchor stud brackets in place with the
5/16-18 carriage bolts installed. Slide them from the inside
towards the outside of the van.
Slide the clamping foot brackets down over the top of the
anchor stud brackets.
Attach the side rails to the 5/16-18 carriage bolts with 5/16
flat washers and 5/16-18 nylocks. Leave them slightly loose to
allow for movement when attaching the crossbars. Tighten all bolts
later.
Fasten the rail connecting brackets to the side rails using the
1/4-20 flange head bolts, 1/4 flat washers, and 1/4-20 nylocks.
Align the side rails and butt them tight to each other as you
tighten down the connecting bracket bolts.
Place the crossbars in the desired location, loosely bolting
the 1/4-20 flange head screws in place. Leave one crossbar aside
for mounting the fairing.
Mount the fairing on the crossbar that was left aside using the
driver rail fairing bracket, passenger rail fairing bracket, center
fairing bracket, driver fairing bracket, passenger fairing bracket,
and fairing gasket.
Check all mounting points and attachments prior to use, and
regularly inspect the product for wear and damage.

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Installation Guide
PRODUCT IMAGE
Low Pro Roof Rack 159 HR
PM0102B
FLATLINE VAN CO · [email protected] · 888-667-5576

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

THANK YOU!
ARE YOU EXCITED ABOUT YOUR NEW LOW PRO ROOF RACK? 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. -5/32″ HEX KEY ALLEN WRENCH -7/16″ WRENCH OR SOCKET -1/2″ WRENCH OR SOCKET

TOOLS

7/16″ WRENCH

1/2″ WRENCH

5/32 ALLEN KEY

FLATLINE VAN CO · [email protected] · 888-667-5576

PACKAGE CONTENTS

DRIVER FRONT RAIL QTY-1

DRIVER REAR RAIL QTY-1

PASSENGER FRONT RAIL QTY-1

PASSENGER REAR RAIL QTY-1

CROSSBAR QTY-6

RAIL CONNECTING BRACKET QTY-2

DRIVER RAIL FAIRING BRACKET
QTY-1

PASSENGER FAIRING BRACKET
QTY-1

CENTER FAIRING BRACKET QTY-1

DRIVER FAIRING BRACKET QTY-1

PASSENGER RAIL FAIRING BRACKET
QTY-1

ANCHOR STUD BRACKET QTY-8

CLAMPING FOOT BRACKET
QTY-8

FAIRING GASKET QTY-1

FAIRING QTY-1

STICKER PACK QTY-1

FLATLINE VAN CO · [email protected] · 888-667-5576

HARDWARE PACK

PM0102B

1/4-20 FLANGE HEAD SCREW
QTY-46

1/4 FLAT WASHER QTY-28

1/4-20 FLANGE HEAD SCREW (SHORT)
QTY-6

5/16 SPRING LOCK WASHER
QTY-16

T-NUT INSERT QTY-6

5/16-18 CARRIAGE BOLT QTY-16

1/4-20 NYLOCK QTY-22

5/16-18 NYLOCK QTY-16

1/4 SPRING LOCK WASHER QTY-6

5/32 ALLEN KEY QTY-1

FLATLINE VAN CO · [email protected] · 888-667-5576

LET’S GET STARTED!

FIRST STEP IS TO PLACE THE ANCHOR STUD BRACKETS IN PLACE WITH THE

5/16-18 CARRIAGE BOLTS INSTALLED. SEE THE DIAGRAM BELOW AS WELL IS

FIGURE 1 TO LEFT FOR REFERENCE

NOTE- THE ANCHOR STUD BRACKET SLIDES UNDER THE ANCHOR

STUD ON THE ROOF. WE PREFER TO SLIDE THEM FROM THE INSIDE

TOWARDS THE OUTSIDE OF THE VAN.

ONCE ALL OF THE ANCHOR STUD BRACKETS HAVE BEEN PLACED, SLIDE THE

CLAMPING FOOT BRACKETS DOWN OVER THE TOP OF THEM AS SHOWN IN

FIGURE 2

ANCHOR STUD BRACKET

FIGURE 1 FIGURE 2

FLATLINE VAN CO · [email protected] · 888-667-5576

NOW YOU CAN START ATTACHING THE SIDE RAILS TO THE 5/16-18

CARRIAGE BOLTS WITH 5/16 FLAT WASHERS, AND 5/16-18 NYLOCKS AS

SHOWN IN FIGURE 3. MAKE SURE TO LEAVE THEM A LITTLE LOOSE TO ALLOW

FOR MOVEMENT WHEN ATTACHING THE CROSSBARS

NOTE- YOU WILL COME BACK TO TIGHTEN ALL BOLTS LATER.

ONCE YOU’VE GOT ALL THE SIDE RAILS UP, FASTEN THE RAIL CONNECTING

BRACKETS TO THE SIDE RAILS USING THE 1/4-20 FLANGE HEAD BOLTS, 1/4

FLAT WASHERS, AND 1/4-20 NYLOCKS (SEE FIGURE 4)

NOTE- ALIGN THE SIDE RAILS AND BUTT THEM TIGHT TO EACH

OTHER AS YOU TIGHTEN DOWN THE CONNECTING BRACKET BOLTS.

FIGURE 4

FIGURE 3

FLATLINE VAN CO · [email protected] · 888-667-5576

PLACE YOUR CROSSBARS IN DESIRED LOCATION, LOOSELY BOLTING THE

1/4-20 FLANGE HEAD SCREWS IN PLACE.

NOTE- LEAVE ONE (1) CROSSBAR ASIDE FOR MOUNTING THE FAIRING

WHEN PLACING CROSSBARS; KEEP IN MIND THE LAYOUT OF YOUR

ROOF TOP ARRAY (SOLAR PANELS, FANS, TENTS, ETC.) YOU CAN

MOUNT CROSSBARS IN THE SET PAIR OF HOLES (SEE FIGURE 5), OR

YOU CAN PLACE THEM IN THE SLOTS WHICH PROVIDES YOU MORE

FREEDOM OF LAYOUT.

AFTER PLACING YOUR CROSSBARS, GO BACK DOWN AND GRAB THE CROSS

BAR YOU SET ASIDE TO BEGIN PUTTING TOGETHER THE FAIRING ASSEMBLY.

YOU WANT TO START WITH THE THREE (3) FAIRING BRACKETS SHOWN

BELOW, AND BOLT THEM TIGHT TO THE CROSSBAR IN THE LOCATIONS

SHOWN IN FIGURE 7 USING THE 1/4-20 BUTTON HEAD SCREWS, 1/4 SPLIT

LOCK WASHERS, AND T-NUT INSERTS AS SHOWN IN FIGURE 6

PRO TIP- IT IS EASIEST TO BARELY GET THE T-NUT INSERTS

THREADED ON TO THE BOLT AND THEN SLIDE THE BRACKETS ONTO

THE CROSSBAR FROM ONE END TO THE APPROPRIATE POSITION.

FAIRING BRACKETS

FIGURE 5
OR
FIGURE 6

FIGURE 7

29.25″

12″

FLATLINE VAN CO · [email protected] · 888-667-5576

NEXT, GRAB THE FAIRING (PLASTIC) AND THE FAIRING GASKET, AND BEGIN

INSTALLING THE GASKET BY PRESSING IT ONTO THE LOWER EDGE OF THE

FAIRING WITH THE BULB SIDE OF THE GASKET TO THE INSIDE (SHINY SIDE)

OF THE PLASTIC. SEE FIGURE 8 & 9 BELOW.

ONCE YOU HAVE THE GASKET INSTALLED, GRAB THE FAIRING ASSEMBLY YOU PUT TOGETHER IN STEP 3, THE PLASTIC FAIRING, AND THE PASSENGER AND DRIVER SIDE RAIL FAIRING BRACKETS AND BEGIN BOLTING THEM TOGETHER AS SHOWN IN FIGURE 10 UTILIZING A 1/4-20 FLANGE HEAD SCREW, 1/4 FLAT WASHER, AND 1/4 NYLOCK FOR EACH MOUNTING HOLE. THE WASHER GOES UNDERNEATH THE NYLOCK NUT. DO NOT OVER-TIGHTEN THESE CONNECTIONS; SNUG IS PLENTY! THE MOUNTING HOLES ARE ALL SLOTTED FOR SMALL ADJUSTMENTS THAT MAY NEED TO BE MADE WHEN ATTACHING THE FAIRING ASSEMBLY TO THE ROOF RACK.

FIGURE 11 TO THE RIGHT SHOWS THE FAIRING ASSEMBLY COMPLETE; WITH IT IN HAND, CONTINUE TO NEXT STEP.

FIGURE 8

FIGURE 11 FIGURE 9

FIGURE 10

FLATLINE VAN CO · [email protected] · 888-667-5576

THIS NEXT STEP IS EASIER WITH THE HELP OF A SECOND PERSON. YOU NEED

TO SLIDE THE FAIRING ASSEMBLY INTO THE FRONT OF THE RACK AS SHOWN

IN FIGURE 13. ONCE IN PLACE, THREAD TWO (2) 1/4-20 FLANGE HEAD

SCREWS INTO THE CROSSBAR ON EITHER SIDE. THEN GRAB TWO (2) EACH

1/4-20 FLANGE HEAD SCREW, 1/4 FLAT WASHER, AND 1/4 NYLOCK AND BOLT

THE RAIL FAIRING BRACKETS TO THE SIDE RAILS. FIGURE 12 TO THE RIGHT

SHOWS THE INSIDE DETAIL. THE BRACKETS ARE SLOTTED FOR ADJUSTMENT.

NOTE- THE BOLTS JOINING THE RAIL FAIRING BRACKETS TO THE RAIL

SHOULD BE TIGHTENED DOWN, BUT REMEMBER THAT ONCE

YOU ADJUST THE FAIRING INTO POSITION; THE BOLTS

SHOULD ONLY BE SNUGGED.

FIGURE 12

FIGURE 13 FRONT
FLATLINE VAN CO · [email protected] · 888-667-5576

BACK 9

FIGURE 14

TIGHTEN ALL CROSSBAR BOLTS USING THE 5/32 ALLEN KEY (SEE FIGURE 14)

NOTE- DO NOT OVERTIGHTEN! IF YOU ARE CONCERNED ABOUT THE

BOLTS BACKING OUT, YOU CAN PUT A DAB OF BLUE LOCTITE ON

THE BOLTS BEFORE TIGHTENING DOWN COMPLETELY.

FIGURE 15

10.

NOW TIGHTEN SIDE RAILS DOWN TO THE LANDING PADS. READY TO HIT THE ROAD!

FLATLINE VAN CO · [email protected] · 888-667-5576

GET OUT AND EXPLORE!
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thanks!

FLATLINE VAN CO · [email protected] · 888-667-5576