FVC TR0109B User manual

PROD
UCT I
MAGE
TR0109B
Safari Rack Drop Front 148 HR
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

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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
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FLATLINE VAN CO • [e-mail] • 888-667-5576
SIDE RAIL WELDMENT (34")
QTY - 4
REAR BASKET WELDMENT
QTY - 1
DROP FRONT WELDMENT
QTY - 1
DROP DOWN WELDMENT
QTY - 1
SIDE RAIL WELDMENT (20.5")
QTY - 2
FOOT BRACKET
QTY - 8
LADDER
BRACKET
QTY - 1
FRONT DECK PANEL
QTY - 1
FAN SIDE DECK PANEL
QTY - 4
MID SECTION DECK PANEL
QTY - 1
REAR DECK PANEL
QTY - 1
FAN COVER PANEL
QTY - 2
BAYONET
QTY - 8
54.5" CROSSBAR
QTY - 4
F45 MOUNTING BRACKET
QTY - 3

HARDWARE
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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 - 34
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 - 37
3/8-16 X 1 SQUARE
NECK CARRIAGE
BOLT
QTY - 26
1/4 SCREW FLAT
WASHER
QTY - 18
3/8 SCREW FLAT
WASHER
QTY - 26
3/8-16 NYLON INSERT
LOCKNUT
QTY - 26
1/4-20 NYLON INSERT
LOCKNUT
QTY - 18
5/16 SCREW BONDED
SEALING WASHER
QTY - 8
1/4-20 T-NUT
QTY - 37
1/4-20 CLIP NUT
QTY - 6

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. 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.
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M8-1.25 X 30 HEX
HEAD SCREW
5/16 SCREW BONDED
SEALING WASHER
FACES OUTSIDE OF VAN

FLATLINE VAN CO • [e-mail] • 888-667-5576
SIDE RAIL ASSEMBLY
Next you need to put together both Side Rail Assemblies. They
are handed Left and Right (mirrors of each other) with a 20.5”
Weldment in the Rear, and two (2) 34” Weldments 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
SIDE RAIL WELDMENT (34")
SIDE RAIL WELDMENT (20.5")
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 X 1 SQUARE NECK
CARRIAGE BOLT
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.
Remember that the end with the shorter (20.5”) weldment goes
towards the rear of the van. As you set the assembly down on top
of the Foot Brackets, the end of the assembly should line up with
one (1) slot on the Foot Bracket as shown in the diagram below.
Insert your hardware as shown, thread them down, but leave it
loose enough to adjust the Side Rail Assembly.
MOUNTING SIDE RAILS TO ROOF
REAR
FRONT

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 Drop Front Weldment, and then on the next
page we’ll tackle the Drop Down Weldment.
Note- The front gets an extra set of hardware installed on
the support channel as shown below in the detail image.
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FRONT
BACK
INSTALLING FRONT AND REAR WELDMENTS