EVO Manufacturing EVO-3038 User manual

EVO Manufacturing
EVO-3038/3038B JL Unlimited Trail Rack
READ BEFORE INSTALLATION:
This rack has a distributed dynamic load rating of 70kg / 154lbs. Applying a bead of RTV Silicone in
drip rail before inserting rack rails is advised for higher loads/speeds. It is advised to not carry items
at high speeds that can create lift (upward force to due to wind) such as but not limited to kayaks and
surfboards etc.

1. On a flat level surface. Begin by assembling the 3 inner slat assemblies. Each will consist of 2
“L” Slat pieces and 1 “T” slat pieces. Using supplied ¼” bolt, washer and flange nuts, assemble 3
sets of inner slat assemblies by installing 6 bolts on the 6 inner holes of each. The end 2 holes
on each end of each slat assembly should remain without bolts at this time. Tighten bolts of all
3 assemblies.
2. Assemble the front and rear slat assemblies next. These will consist of 1 “L” Slat piece and 1 “T”
flat piece. Using supplied ¼” bolt, washer and flange nuts, assemble 2 sets of end (front and
rear) slat assemblies by installing bolts on the 3 inner holes only. The end 2 holes and other
middle 3 holes should remain without bolts at this time. Tighten 3 bolts on both front and rear
assemblies. Front and rear assemblies are duplicates of each other.

3. On a flat surface. Loosely assemble the perimeter sections of the rack. This consists of the
Driver side plate, Passenger side plate, Front plate and Rear plate. Using the supplied ¼” bolts,
washer and flange nut loosely install 2 sets at each corner.
4. Using supplied ¼” bolt, washer and flange nuts, loosely install the 3 pre-assembled middle cross
bar slats, front and rear cross bar slat. All cross bar assemblies should be installed on the
underside of the perimeter parts.

5. Using supplied 5/16” bolt, washer, flange nut. Install upper bolt plate and lower bolt plate as
shown. Install bolt from inside toward the outside. Tighten bolts. Do this at all 4 ends.

6. With rack loosely assembled and upside down. Flip over if needed. Install/press on edge trim
on driver side plate edge end to end. Trim and use remainder to repeat on passenger side plate.
7. This may require 2 or more people. Flip rack with top up. Lift over jeep hard top and set into
place on into the drip rail. Rack should be placed where the rear edge of the side plates line up
with the rear of the drip rail. The rack may require a slight push to fully seat into drip rail.
8. Install edge trimming on the edge of the 4 outer rail mounting plate lips.
9. Using the supplied 3/8 bolt and lock washer, addition of Loctite or similar product on bolt
threads is recommend for this step. Insert bolt and washer from top down of upper mounting
plate and thread into outer rail mount. Lower edge with trim should be grabbing underside of
hardtop drip rail. Do not over tighten this bolt. Snug to 15 lb/ft. Repeat on all 4 mounting ends.

10. Tighten all loose bolts.

Size
Recommended Torque
Grade 2
Grade 5
Grade 8
18-8 S/S
Bronze
Brass
Coarse
Fine
Coarse
Fine
Coarse
Fine
Coarse
Fine
Coarse
Fine
Coarse
Fine
#4*
-
-
-
-
-
-
5.2
-
4.8
-
4.3
-
#6*
-
-
-
-
-
-
9.6
-
8.9
-
7.9
-
#8*
-
-
-
-
-
-
19.8
-
18.4
-
16.2
-
#10*
-
-
-
-
-
-
22.8
31.7
21.2
29.3
18.6
25.9
1/4
4
4.7
6.3
7.3
9
10
6.3
7.8
5.7
7.3
5.1
6.4
5/16
8
9
13
14
18
20
11
11.8
10.3
10.9
8.9
9.7
3/8
15
17
23
26
33
37
20
22
18
20
16
18
7/16
24
27
37
41
52
58
31
33
29
31
26
27
1/2
37
41
57
64
80
90
43
45
40
42
35
37
9/16
53
59
82
91
115
129
57
63
53
58
47
51
5/8
73
83
112
128
159
180
93
104
86
96
76
85
3/4
125
138
200
223
282
315
128
124
104
102
118
115
7/8
129
144
322
355
454
501
194
193
178
178
159
158
1†
188
210
483
541
682
764
287
289
265
240
235
212