FVC TR0106B User manual

PROD
UCT I
MAGE
TR0106B
Safari Rack Basket Front 148 MR
Installation Guide
FLATLINE VAN CO • [e-mail] • 888-667-5576

1
FLATLINE VAN CO • [e-mail] • 888-667-5576
THANK YOU!
ARE YOU EXCITED ABOUT YOUR NEW SAFARI 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.
-13MM BOX WRENCH OR SOCKET
-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 13MM WRENCH

2
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.
thanks.

PACKAGE CONTENTS
3
FLATLINE VAN CO • [e-mail] • 888-667-5576
SIDE RAIL WELDMENT (34")
QTY - 6
REAR BASKET WELDMENT
QTY - 1
FRONT BASKET WELDMENT
QTY - 1
MID ROOF FOOT BRACKET
QTY - 6
LADDER
BRACKET
QTY - 1
FAN SIDE DECK PANEL
QTY - 4
MID SECTION DECK PANEL
QTY - 1
REAR DECK PANEL
QTY - 2
FAN COVER PANEL
QTY - 2
BAYONET
QTY - 8
54.5" CROSSBAR
QTY - 5
F45 MOUNTING BRACKET
QTY - 3
SUPPORT FOOT BRACKET
QTY - 2
DRIVER SIDE SUPPORT
BRACKET
QTY - 1
PASSENGER SIDE SUPPORT
BRACKET
QTY - 1
FOOT BRACKET
QTY - 2
MID ROOF MID SECTION
DECK PANEL
QTY - 1

HARDWARE
4
FLATLINE VAN CO • [e-mail] • 888-667-5576
M8-1.25 X 30 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
1/4-20 X 0.5 FLANGED
BUTTON HEAD HEX
DRIVE SCREW
QTY - 44
3/8-16 X 1 SQUARE
NECK CARRIAGE
BOLT
QTY - 30
1/4 SCREW FLAT
WASHER
QTY - 8
3/8 SCREW FLAT
WASHER
QTY - 38
3/8-16 NYLON INSERT
LOCKNUT
QTY - 34
1/4-20 NYLON INSERT
LOCKNUT
QTY - 8
5/16 SCREW BONDED
SEALING WASHER
QTY - 8
1/4-20 T-NUT
QTY - 44
1/4-20 CLIP NUT
QTY - 6
3/8-16 X 1 BUTTON
HEAD HEX DRIVE
SCREW
QTY - 4

FLATLINE VAN CO • [e-mail] • 888-667-5576
FOOT BRACKETS
Mounting the Foot Brackets is the first step. You will need to first pry o
the access covers on the roof of your van to reveal the access holes.
Some vans require some clearance to be made in the access holes due
to build tolerance from Ford Factory (shown right). Be sure to use touch
up paint on any bare metal to prevent rusting.
Now you can mount the Foot Brackets to the roof. There are two types
of Foot Brackets for the Mid Roof Transit. The two Foot Brackets shown
below on left mount in the rear most position on either side of your van.
The flange with the single hole and rubber gasket attaches to the van
using a M8-1.25 X 30 Hex Head Screw and 5/16 Screw Bonded Sealing
Washer. The top flange faces the outside of the van. Make sure the
bracket is straight and square before applying sealant. We recommend
using Teroson MS 5510 BK. Applying the sealant is for peace of mind to
ensure a leak free installation. You can also perform this after the Side
Rail Assemblies (next step) have been installed if you are concerned
about bracket fitment.
5
M8-1.25 X 30 HEX
HEAD SCREW
5/16 SCREW BONDED
SEALING WASHER
FACES OUTSIDE OF VAN
FOR REAR MOST POINTS
OF VAN ONLY

FLATLINE VAN CO • [e-mail] • 888-667-5576
SIDE RAIL ASSEMBLY
Next you need to put together both Side Rail Assemblies. Three
34” Weldments need to be mated together as shown below. Page
7 shows details views and hardware used.
We recommend putting these together on a larger flat table, or
spreading out the cardboard from your shipping box. Using some
quick clamps to draw the segments together while you’re tighten
hardware down makes it much easier.
6
REAR
FRONT

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

FLATLINE VAN CO • [e-mail] • 888-667-5576 8
3/8-16 NYLON INSERT LOCKNUT
3/8 SCREW FLAT WASHER
In this step you’ll be mounting the Side Rail Assemblies to the
roof of the van. It is very helpful to have multiple ladders and
someone else to help, but this can be done by one person,
carefully.
Use the diagram below to show you wear to insert hardware and
how the side rail rests on the Foot Brackets. The rear of the Side
Rail should straddle the rear most Foot Bracket to allow the Rear
Basket Weldment to overlap once installed.
MOUNTING SIDE RAILS TO ROOF
REAR
FRONT
SIDE RAIL STRADDLES
BRACKET IN REAR
3/8-16 X 1 SQUARE NECK CARRIAGE BOLT

FLATLINE VAN CO • [e-mail] • 888-667-5576
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 Basket Front Weldment.
Note- The Basket Front Weldment has the FVC Badge on
the corner.
9
FRONT
BACK
INSTALLING FRONT AND REAR WELDMENTS