FVC SP0108B User manual

PROD
UCT I
MAGE
SP0108B
Sprinter Safari Rack Drop Down 170
Installation Guide
FLATLINE VAN CO • [e-mail] • 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.
1
FLATLINE VAN CO • [e-mail] • 888-667-5576
thanks.

2
FLATLINE VAN CO • [e-mail] • 888-667-5576
THANK YOU!
ARE YOU EXCITED ABOUT YOUR NEW PRODUCT NAME? 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
5/32 ALLEN KEY
3/8 WRENCH
7/16 WRENCH 9/16 WRENCH

PACKAGE CONTENTS
3
FLATLINE VAN CO • [e-mail] • 888-667-5576
SPRINTER SAFARI RAIL MOUNT
QTY - 10
F45 MOUNTING BRACKET
QTY - 3
FLOOR SECTION 2
QTY - 2
FLOOR SECTION FAN SIDE PANEL
QTY - 4
FLOOR SECTION FAN COVER
QTY - 2
FLOOR SECTION 4
QTY - 1
FLOOR SECTION 1
QTY - 1
FLOOR SECTION 5
QTY - 1
FLOOR SECTION 8
QTY - 1
47.5" CROSSBAR
QTY - 7
BAYONET
QTY - 10
SIDE RAIL WELDMENT
QTY - 8
170 REAR BASKET WELDMENT
QTY - 1
DROP DOWN WELDMENT
QTY - 1
OPEN FRONT WELDMENT
QTY - 1

HARDWARE
4
FLATLINE VAN CO • [e-mail] • 888-667-5576
SPRINTER RAIL NUT
QTY - 10
0.375-16 X 1 SQUARE NECK
CARRIAGE BOLT
QTY - 26
3/8-16 X 0.75 FLANGED HEX
HEAD SCREW
QTY - 10
3/8-16 NYLON INSERT LOCKNUT
QTY - 26
3/8 SCREW FLAT WASHER
QTY - 26
3/8 SCREW BELLEVILLE SPRING
LOCK WASHER
QTY - 10
1/4-20 X 0.75 FLANGED HEX
HEAD SCREW
QTY - 50
1/4-20 X 0.75 FLANGED BUTTON HEAD
HEX DRIVE SCREW
QTY - 46
1/4-20 X 0.5 FLANGED BUTTON
HEAD HEX DRIVE SCREW
QTY - 57
1/4-20 NYLON INSERT LOCKNUT
QTY - 28
1/4-20 ECONOMY T-NUT
QTY - 57
1/4 SCREW FLAT WASHER
QTY - 22

FLATLINE VAN CO • [e-mail] • 888-667-5576
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 8 SIDE RAIL
WELDMENTS, 10 BAYONETS, AND 10 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.
5
FIGURE 1

FLATLINE VAN CO • [e-mail] • 888-667-5576 6
DETAIL B DETAIL C
DETAIL A
DETAIL D
1/4-20 X 0.75 FLANGED HEX
HEAD SCREW
1/4-20 X 0.75 FLANGED BUTTON HEAD
HEX DRIVE SCREW
1/4-20 NYLON INSERT LOCKNUT
1/4 SCREW FLAT WASHER
0.375-16 X 1 SQUARE NECK
CARRIAGE BOLT
3/8-16 NYLON INSERT LOCKNUT
3/8 SCREW FLAT WASHER

FLATLINE VAN CO • [e-mail] • 888-667-5576 7
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

FLATLINE VAN CO • [e-mail] • 888-667-5576
5. WE RECOMMEND HAVING A SECOND SET OF HANDS TO HELP WITH THIS STEP
AS WELL. START WITH THE REAR BASKET 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 OPEN FRONT.
NOTE- REMEMBER TO LEAVE THE RAIL MOUNT FEET LOOSENED.
WE’LL TIGHTEN THOSE DOWN IN A LATER STEP.
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FIGURE 3
FRONT
BACK

FLATLINE VAN CO • [e-mail] • 888-667-5576 9
6. NEXT WE’LL GET THE DROP DOWN WELDMENT MOUNTED UP. THE DROP
DOWN MOUNTS TO THE UNDERSIDE TRAY OF THE OPEN FRONT WELDMENT.
YOU WILL NEED TO MANEUVER IT AROUND YOUR ANTENNA TO GET IT IN
PLACE, SO HAVING A SECOND PERSON HELPS IMMENSELY FOR THIS STEP.
DETAIL E & F DISPLAY HOW IT FASTENS TO THE OPEN FRONT WELDMENT.
NOTE- WE RECOMMEND INSTALLING YOUR LIGHTING SETUP TO THE
DROP DOWN WELDMENT PRIOR TO INSTALLING IT ON THE RACK. THIS
MAKES ADJUSTMENTS AND PLACEMENT A BIT EASIER.
FIGURE 4
1/4-20 X 0.75 FLANGED HEX
HEAD SCREW
1/4-20 NYLON INSERT LOCKNUT
1/4 SCREW FLAT WASHER
DETAIL E
DETAIL F
BOLTING LOCATIONS

FLATLINE VAN CO • [e-mail] • 888-667-5576
7. 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.
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FRONT BACK
REFERENCE POINT
FIGURE 4
0" 5 1
16
"
34 1
16
"
49 9
16
"
78 9
16
"
112 9
16
"
141 9
16
"
157 1
16
"
DETAIL E
1/4-20 X 0.75 FLANGED HEX
HEAD SCREW

FLATLINE VAN CO • [e-mail] • 888-667-5576
8. 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.
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AWNING MOUNTS DETAIL F
AWNING BRACKET
FIGURE 5
FRONT BACK
REFERENCE POINT
0 23 1
2
"
81 1
2
"
159 1
2
"

FLATLINE VAN CO • [e-mail] • 888-667-5576
9. 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.
10. START WITH THE REAR FLOOR SECTION FIRST AND WORK YOUR WAY UP.
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.
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DETAIL H
DETAIL G
DETAIL J

FLATLINE VAN CO • [e-mail] • 888-667-5576 13
FRONT
BACK
• FLOOR SECTION 2
• FLOOR SECTION FAN SIDE PANEL
• FLOOR SECTION FAN COVER
• FLOOR SECTION 4
• FLOOR SECTION 1
• FLOOR SECTION 8
REMOVABLE FOR MAXXAIR FAN
• FLOOR SECTION 5
• FLOOR SECTION 2

FLATLINE VAN CO • [e-mail] • 888-667-5576 14
11. 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!

FLATLINE VAN CO • [e-mail] • 888-667-5576 15
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outdoor enthusiasts that design and use our own products, so we want you to be as stoked on your new parts as we are!
thanks!
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