Let's Go Aero BLACK BOX User manual

PAGE 1 OF 21
BLACK BOX
Slide-Out Enclosed Cargo Carrier System
Set Item Product
BBOXManual-031819Rev
PRODUCT MANUAL
For More Information & Accessories, Visit our Website - www.LetsGoAero.com
For Technical Support & Product Questions Contact Us at 877-464-2376 or 719- 630-3800
Email: [email protected]
READ THIS MANUAL THOROUGHLY.
BE SURE TO READ ALL WARNINGS BEFORE OPERATION.
Installation & Safe Use Operation Highlights
Fits 2” size receiver hitches.
Rated for 300 lbs of cargo payload. 160 lbs empty weight.
Class II minimum tow rating required; Class III recommended.
Parts & Tools List ............................................................................................... 2
Installation .......................................................................................................... 3
Open & Closing Operation ................................................................................. 19
Slide-Out Operation ........................................................................................... 20
Warranty & Registration ..................................................................................... 21
Description Page
BLACK BOX SYSTEM - ASSEMBLY, INSTALLATION, AND OPERATION INSTRUCTIONS:

PAGE 2 OF 21
A
B
C
D
E
F
G
H
I
J
1
2
1
1
1
1
2
1
2
1
FLATPIPE™ SPINE
RETAINER CLIP
5/8” SILENT HITCH PIN®
HAND-TIGHTEN PIN
5/8” LOCK WASHER
5/8” PLASTIC BUSHING
5/8” SPRING NUT
WAX
RUBBER BUMPER
5/8” FLAT WASHER
FLATPIPE™ PLATFORM
QTY. DESCRIPTION
NOTE: End Tubes [X] and four (4) Square End Caps [DD] are for open rack (GearCage) assembly only. You may save
these parts for future use or discard them. See GearCage Rack assembly manual for open rack assembly.
RACK PARTS LIST & ASSEMBLY OVERVIEW
VV
WW
XX
YY
ZZ
AAA
BBB
CCC
DDD
EEE
FFF
GGG
HHH
III
JJJ
KKK
LLL
MMM
NNN
AERFOIL COVER
BULKHEAD
BULK HEAD WITH HANDLE
1/4-20 JOINT SOCKET HEAD BOLT
1-4-20 PIN NUT (BLACK)
3.5” x 1/4” BOLT
1/4” x 20 NYLOCK NUT
43” AERFOIL BAND
BAND SPRING
LIFT PLATES
LIFT ARMS
GAS SHOCKS
3/8” NYLOCK NUTS
7/8” SELF TAPPING SCREWS
10-24 x 1 SCREW
5/16” WASHER
10-24 NYLOCK NUT
1/4” SPLIT RING WASHERS
SUPPORT BAND
AERFOIL LID (Black Box Cover)
S
T
U
V
W
X
Y
Z
AA
BB
CC
DD
EE
FF
GG
HH
3
2
4
2
16
6
12
6
8
4
12
8
2
6
4
4
FLOOR PANEL
SIDE RAIL
U-TUBE
END TUBE (OPEN RACK ONLY)
8MM X 70MM BUTTON HEAD BOLT
6MM X 20MM BUTTON HEAD BOLT
M6 WASHER
M6 NYLOCK NUT
6MM X 50MM BUTTON HEAD BOLT
6MM X 30MM BUTTON HEAD BOLT
PIN NUT
SQUARE END CAPS
FRAME BAR
K-LATH SELF TAPPING SCREW
SPACERS
PLUG
RACK & SIDE PANEL
QTY. DESCRIPTION
K
L
M
N
O
P
Q
R
2
2
4
8
18
18
2
1
FEMALE TUBES
FRAME ANGLES
HAT BRACKETS
M8 CARRIAGE BOLTS
M8 WASHERS
M8 NUTS
REFLECTOR CAPS
SAFETY CABLE
TWINTUBE FRAME MOUNT
QTY. DESCRIPTION
II
JJ
KK
LL
MM
2
2
1
1
4
8MM X 50MM BUTTON HEAD BOLT
SIDE PANEL
END PANEL WITH HINGES
END PANEL WITH PULL LATCHES
1/4-20 X 3/4 BOLT
RACK & SIDE PANEL
QTY. DESCRIPTION
QTY. DESCRIPTION
NN
OO
PP
QQ
RR
SS
TT
UU
2
1
2
2
4
4
4
2
1
1
1
4
4
2
2
4
2
2
2
2
2
4
4
4
4
4
3
LED LIGHTS
WIRE HARNESS
LED LICENSE PLATE BRACKET
LED MOUNT BRACKET
6mm HEX BOLT
6mm NYLON NUT
6mm WASHER
REFLECTOR STRIPS
LIGHT KIT
QTY. DESCRIPTION
If you are missing any items, contact your sales
agent if the product was assembled by them. If
not, or if purchased from Let’s Go Aero, please
contact us at 1-877-GO-4-AERO (464-2376).
Tools Needed:
1/2” Wrench and Socket
7/16" Wrench and Socket
5/32” Allen Wrench
10 mm Wrench
3/8in Wrench
7/8in Wrench
3/16” Allen Wrench
Center Punch
Drill and Phillips Bit
Phillips Screwdriver
Flathead Screwdriver

PAGE 3 OF 21
Shank
A
Compress one Spring Nut [G] within the FlatPipe Spine [A] end as shown. The
Spring Nut may be installed between either the rst or the second mounting
hole (user choice) [Figure 1].
NOTE: The FlatPipe Spine [A] end (called the “Shank”) contains two (2)
mounting holes. The ideal hole for use is the second hole in from the end of
the shank. If the shank bottoms out inside the receiver hitch, or if you need to
maximize clearance, use the rst hole in from
the end [Figure 2].
NOTE: For proper carrier balance, there is
a 3° pitch on the FlatPipe Spine [A]. Be sure
when installing that your FlatPipe Spine is
right side up [Figure 2].
STEP 1
3° Pitch A
G
1st Hole
2nd Hole
[Figure 1]
[Figure 2]
Hitch Receiver
[Figure 3]
STEP 2 TOOLS: 7/8” SOCKET WRENCH
Slide the shank end of the FlatPipe Spine [A] into the receiver hitch aligning the choosen mounting hole and Spring Nut
[G] with the hole in the receiver hitch [Figure 3]. Secure the Spine with the Silent Hitch Pin [C], one (1) 5/8 Lock Washer
[E], and one (1) 5/8 Flat Washer [J] by threading the Silent Hitch Pin into the Spring Nut [Figure 4].
NOTE: The 5/8 Lock Washer [E] should be located closest to the hex head end of the Silent Hitch Pin [C]. Tighten the
Silent Hitch Pin until the Lock Washer becomes fully compressed.
Attach the Retainer Clip [B] to the end of the Pin.
G
A
Hitch Receiver
G
A
E
J
B
C
[Figure 4]
Never operate the vehicle without the Silent Hitch Pin fully secured with a 7/8” wrench. Failure to do so may result
in bodily injury and property damage. Always check to be sure the Silent Hitch Pin is snug before transit.
WARNING:

PAGE 4 OF 21
STEP 3
Slide one (1) Rubber Bumper [K] onto
each Flat Pipe Spine [A] tube (total 2).
Push the Rubber Bumpers along the
tubes until they sit ush against the
frame of the FlatPipe Spine [Figure 5 &
6].
Using the provided water-proof Wax
Block [J], rub along all four sides of each
Spine tube to completely “coat” the Spine
tubes [Figure 5 & 7].
NOTE: The parafn Wax [J] will remain
in place and clean, however, the Wax
may wear off over time depending on
use. It is recommended to save your
Wax Block in a safe place for future use.
A
J
[Figure 7]
K
[Figure 5]
[Figure 6]
STEP 5
Install Female Tubes [K] over the waxed Flat Pipe [A] tubes
[Figure 9].
NOTE: The holes of both Female Tubes [K] should align with the
holes on the FlatPipe Spine [A] tubes [Figure 9]. AK
[Figure 9]
STEP 4
Insert the remaining Spring Nut [G] into either open end (user choice) of the
FlatPipe Spine [A] tubes.
Align the Spring Nut [G] threading with the hole at the end of the FlatPipe
Spine [A] tube in the same manor as STEP 1 [Figure 8].
NOTE: Placement of the Spring Nut [G] is left to user discretion for either
left handed or right handed use. The user may place the Spring Nut in either
side of the Flat Pipe Spine tubes [A].
AG
[Figure 8]

PAGE 5 OF 21
Q
STEP 7
Secure the Reector Caps [Q] to the open ends of the Female Tubes [K]. [Figure 11].
K
[Figure 11]
STEP 6
Slide the 5/8 Plastic Bushing [F] onto the Hand-Tighten Silent Hitch
Pin [D].
In the same manor as Step 2, insert and thread the Hand-Tighten
Silent Hitch Pin [D] with the Plastic Bushing [F] through the Flat Pipe
[A], Female Tubes [K] and internal Spring Nut [G] [Figure 10]. Secure
with Retainer Clip [B].
NOTE: The Hand-Tighten Silent Hitch Pin [D] controls the slide out
function of the BlackBox Carrier. Once installation is complete, the
Hand-Tighten Silent Hitch Pin may be removed and the carrier can be
slide rearward for rear hatch/door access. [Figure 10]
D
K
B
G
F
Never operate vehicle without the Hand-Tighten Silent Hitch Pin [D] sufciently tighten to prevent the carrier from
sliding while in transit. Failure to do so may result in bodily injury and property damage.
WARNING:
STEP 8
Set one Frame Angle [L] on top of the Female Tubes
[K].
NOTE: Be sure that this Frame Angles’ [N] shorter
end faces away from the vehicle as shown.
Bring one (1) Hat Bracket [M] up from underneath
each Female Tube [K] to connect to the Frame Angle
[L],
Using two (2) M8 Carriage Bolts [N], two (2) M8
Washers [O], and two (2) M8 Nuts [P] connect each
Hat Bracket [M] to the Frame Angle [L] as shown
[Figure 12].
Hand-Tighten only at this time, further adjustment
will be required before nal assembly.
O
P
AL
K
M
N
[Figure 12]

PAGE 6 OF 21
STEP 9
Set the remaining Frame Angle [L] onto of Female
Tubes [K] as shown.
This Frame Angle [L] is positioned closer to the vehicle
than the Frame Angle from the last step.
NOTE: This Frame Angle [L] is “mirrored” and
positioned with the shorter end facing towards the
vehicle as shown.
In the same manor as Step 8, attach one (1) Hat
Bracket [M] to each Female Tube [K] using two (2)
M8 Carriage Bolts [N], two (2) M8 Carriage Washers
[O], and two (2) M8 Nuts [P] on each side, adding the
“looped end” of the Safety Cable [R] between the Hat
Bracket and Frame Angle [L] on one side only [Figure
13].
NOTE: The Safety Cable must be placed on the
interior of the Female Tube [K] assembly as shown.
Hand-Tighten only at this time, further adjustment
will be required before nal assembly.
O
P
R
M
The Safety Cable prevents the BlackBox Carrier from sliding off the FlatPipe Spine when telescoped. The rack may
be slid out when parked for vehicle hatch access only. Never move the vehicle while the carrier is slid out. Failure to
engage the Safety Cable and follow product guidelines may result in bodily injury and property damage.
WARNING:
N
L
K
[Figure 13]
Lay one (1) Frame Bar [EE] on each newly
installed Frame Angle [L].
NOTE: Frame Bars [EE] have mounting
holes on only two sides and are NOT
interchangeable with the Side Rails [T] to be
used in STEP 14.
Using the center mounting holes, attach the
Frame Bars [EE] to the Frame Angles [L] using
two (2) 8mm x 50mm Button Head Bolt [II],
two (2) M8 Washers [O], and two (2) M8 Nuts
[P] as shown [Figure 14].
NOTE: These bolts are installed upside-down
as shown.
Fully secured these connections.
STEP 10
EE
II
O
P
L
[Figure 14]
TOOLS: 1/2” WRENCH & 3/16 HEX KEY

PAGE 7 OF 21
Adjust the distance between the Frame Angles [L] so
the Frame Bars [EE] are approximately 18in apart.
Lay the four (4) U-Tubes [U] on top of the Frame Bars
[EE] [Figure 15].
The holes in the Frame Bars [EE] should line-up and
match with the holes in the bottom of the U-Tube [U].
STEP 11
U
EE
L
[Figure 15]
STEP 12
W
EE
O
P
U
S
L
[Figure 16]
TOOLS: 1/2” WRENCH & 3/16 HEX KEY
Lay two (2) Floor Panels
[S] over the U-Tubes [U].
NOTE: The third/center
Floor Panel [S] is not
attached in the same
manor as the two (2) Floor
Panels in this step and
should not applied at this
time.
NOTE: The holes in the
Floor Panels [S], U-Tubes
[U], Frame Bars [EE] and
Frame Angles [L] must
align.
Connect the Floor Panels
[S], U-Tubes [U] and
Frame Bars [EE] using
eight (8) 8mm x 70mm
Button Head Bolt [W], eight
(8) M8 Carriage Washers
[O], and eight (8) M8 Lock
Nuts [P] [Figure 16].
Fully secured these
connections.

PAGE 8 OF 21
Lay the nal Floor Panel [S] in the center of
the carrier on top of the U-Tubes [U] [Figure
17].
From the underside of the carrier, secure the
center Floor Panel [S] to the Floor Panels
from Step 12 using six (6) 8mm x 20mm
Button Head Bolts [X], twelve (12) 6mm
Washers [Y], and six (6) 6mm Nylock Nuts
[Z] [Figure 18].
Fully secured these connections.
STEP 13
X
Y
Z
S
U
U
S
UNDERNEATH CARRIER VIEW
[Figure 17]
[Figure 18]
TOOLS: 7/16” WRENCH & 5/32 HEX KEY

PAGE 9 OF 21
Using the middle two (2) U-Tubes
[U] only, insert one (1) Pin Nut [CC]
through each hole at the top of the
U-Tubes. [Figure 19]
NOTE: The “slot end” illustrates
the Pin Nuts’ [CC] internal thread
direction.
NOTE: The “notched end” of the Pin
Nut should lock into the edge of the
U-Tube hole as shown [Figure 20].
Place the Side Panels [JJ] and Side
Rails [W] on top of the U-Tubes [U]
with the LARGER holes at the end
of Side Rails face up.
Secure the Side Rails [T] and Side
Panels [JJ] to the U-Tubes [U]
by passing two (2) 6mm x 50mm
Button Head Bolts [AA] through
each Side Rails, threading the Bolts
into the Pin Nuts [CC]. [Figure 21]
Hand tighten only at this time.
CC
T
NOTCH
END
SLOT
END
STEP 14
U
U
JJ
AA
AA
T
CC
AA
[Figure 19]
[Figure 20]
[Figure 21]
Large Hole
TOOLS: 5/32 HEX KEY
Insert one (1) Pin Nut
[CC] into each of the four
(4) remaining mounting
locations at the tops of the
outer U-Tubes [U] in the
same manor as Step 14.
[Figure 22]
Drop one (1) 6mm x
30mm Button Head Bolt
[BB] in to each end of
the Side Rails [T] and
U-Tubes [U] threading into
the Pin Nut [CC] on the
interior of the U-Tubes.
NOTE: The “Button
Head” of the 6mm x
30mm Button Head Bolt
[BB] passes through
larger hole on the top of
the Side Rail [T] and rests
on the inside of the railing
as shown. [Figure 23]
Fully secure all
hardware from STEPS
14 and 15.
STEP 15
U
U
BB
W
T
CC
CC
BB
[Figure 22]
[Figure 23]

PAGE 10 OF 21
With the Side Rails [T] in place. Un-bolt and remove the four (f)
8mm x 70mm Button Head Bolts [W] at each end of the rack oor
allowing the bottom lip of End Panels [KK] & [LL] to slip between
the Frame Bars [EE] and U-Tubes [U] [Figure 24 & 27]. The End
Panel [KK] that includes Hinge hardware must be installed on the
Drivers Side of the Vehicle. With the holes aligned, re-insert the
8mm x 70mm Button Head Bolts [W] [Figure 25 & 26].
Next, using four (4) 8mm x 70mm Button Head Bolts [W], four (4)
Pin Nuts [CC] and four (4) Spacers [GG] on each side, connect
the End Panel [KK] & [LL] to the Side Rail [T] by passing the Bolts
through the over-hanging edge of the End Panel, the Spacers [GG] and through to the base of the End Panel
threading the bolt through the Pin Nut on the interior of the Side Rail [Figure 27]. Fully secure this hardware.
W
W
W
KK
EE
KK
KK
LL
S
U
CC
[Figure 24,
Before]
[Figure 25] [Figure 26]
[Figure 27]
[Figure 28]
STEP 16
W
W
STEP 17
Locate two 3/16” dia. holes in each end
panel. Using the End Panel [KK] & [LL]
as a guide, center punch an indentation
at each hole center. Drill 1/8” dia. holes
through the End Panel into the U-Tube
[U]. Insert and tighten four K-lath Self-
Tapping Screws [FF] [Figure 28].
NOTE: Tip of the K-lath Self-Tapping
Screws [FF] are self-drilling as well. You
may choose to power drive the screws
without pre-drilling if you have the tools
and skill to do so.
GG
FF
TOOL: 1/2” WRENCH & 3/16 HEX KEY, ????????
T

PAGE 11 OF 21
STEP 18
Insert Plugs [HH] into the large holes of the Side Rails
at each corner of the carrier (total 4) [Figure 29].
HH
STEP 19
The BlackBox cargo carrier enjoys between 6in-12in of installed clearance from the vehicle and between 25in-
32in of clearance from the vehicle when slid out.
With the Hat Brackets [M] from STEP 8 & 9 still loosely secured, slide the carrier back and forth along the Female Tubes
[K] to adjust for required vehicle clearances (user discretion).
NOTE: Users wanting more clearance between the tow vehicle and carrier should position the Hat Brackets [M] further
away from the vehicle on the Female Tubes [K] [Figure 30]. DO NOT surpass the Hand-Tighten pin.
NOTE: Users wanting less clearance between the tow vehicle and carrier should position the Hat Brackets [M] closer to
the vehicle on the Slide Tubes [K] [Figure 31]. DO NOT overlap the Hand-Tighten warning sticker.
Once the nal clearance adjustments have made, conrm the aligned Female Tubes [K] are slid all the way back against
the Rubber Bummers [I] and then fully secure all Hat Brackets [M] and hardware from Steps 8 & 9.
NOTE: Be sure to allow room for the Hand-Tighten Hitch Pin [D] to turn and operate as required.
MM
KK
D
D
DO NOT ALLOW HAT BRACKETS TO OVERLAP THE 3.5” WARNING LABEL LOCATED ON
ON THE SLIDE TUBE. Failure to do so will permit overextension of the safety cable allowing the
capsule to fall off and cause damage or personal injury.
WARNING:
MIN INSTALLED CLEARANCE MAX INSTALLED CLEARANCE
WARNING WARNING
[Figure 30] [Figure 31]
[Figure 29]
TOOLS: 1/2” WRENCH

PAGE 12 OF 21
[Figure 34]
STEP 21
STEP 22
QQ
NN
QQ
Attach two (2) LED Mount Brackets [QQ] to
the Side Rail [T] on the side of the carrier
facing away from the vehicle using two (2)
K-Lath Self Tapping Screws [FF] (one per LED
Mount Bracket). [Figure 33].
NOTE: The K-Lath Screw [FF] should be
installed approximately 12in from each end of
the Side Rail centered between the U-Tubes
[U].
Remove the Washer and Nut supplied on the back side of
one (1) LED Light [NN].
On the passenger side of the vehicle, mount the LED Light
[NN] (Green Wire) onto LED Mount Bracket [QQ] using the
supplied Phillips Screw on the LED Light [Figure 34].
Secure the LED Light [NN] to the LED Mount Bracket [QQ]
by re-attaching the supplied Washer and Nut onto the back
of the LED Lights and LED Mount Bracket.
NOTE: The LED Light [NN] with the Green Wire must be
installed on the Passenger side of the Vehicle.
FF
T
U
[Figure 33]
Supplied LED Hardware
TOOLS: TWO (2) 7/16 WRENCH OR SOCKET
TOOLS: 7MM WRENCH & PHILLIPS HEAD SCREW DRIVER
From underneath the carrier, connect the quick-link end
of the Safety Cable [R] to the hole in the frame of the
Flat Pipe Spine [A] [Figure 32].
NOTE: The Safety Cable [R] can be secured in two (2)
positions. Securing the Safety Cable to the 1st Position
is ideal; carriers positioned for maximum clearance will
need to use the 2nd Safety Cable position.
STEP 20
1st Position
2nd Position
Never operate the carrier’s slide out function or the
tow vehicle without conrming the Safety Cable fully
secured. Failure to follow product guidelines may
result in bodily injury and property damage.
WARNING: R
A
[Figure 32] UNDERNEATH CARRIER VIEW

PAGE 13 OF 21
STEP 23
[Figure 25]
[Figure 35]
NN
PP
QQ
Remove the Washer and Nut supplied on the
back side of the remaining LED Light [NN].
On the drivers side of the vehicle, mount the
LED Light [NN] with two License Plate Brackets
[PP] on either side of the LED Mount Bracket
[QQ] using the supplied Phillips Screw on the
LED Light.
Secure the LED Light [NN] and License Plate
Brackets [PP] to the LED Mount Bracket [QQ]
by re-attaching the supplied Washer and Nut
onto the back of the LED Lights and LED Mount
Bracket [Figure 35]. Supplied LED Hardware
TOOLS: 7MM WRENCH & PHILLIPS HEAD SCREW DRIVER
Failure to properly connect the Yellow Wire to the drivers side of the vehicle and the Green Wire to the passenger
side of the vehicle will result in mismatched stop/turn lights and improper signaling.
WARNING:
RR
STEP 24 (OPTIONAL)
STEP 25
Secure (user supplied) License Plate to the
License Plate Brackets [PP] using two (2) 6mm
Hex Bolts [RR], two (2) 6mm Washers [TT] and
two (2) Nylon Nuts [SS] [Figure 36].
Connect the Yellow Wire from the LED Lights [NN] on the drivers side to the Yellow wire on the LED Wire Harness [OO].
Connect the Green Wire from the LED Lights [NN] on the passenger side to the Green wire on the LED Wire Harness
[OO].
Weave the Wire Harness [OO] in a straight path underneath the carrier and connect the Wire Harness 4-Flat connector to
the tow vehicles trailer light connections. OPTIONAL TIP: Wrap the connection ends with Electrical Tape to help ensure
longevity of the wires.
TT
SS
[Figure 36]
TOOLS: TWO (2) 7/16 WRENCH OR SOCKET
PP
OPTIONAL TOOL: ELECTRICAL TAPE

PAGE 14 OF 21
Drivers Side
Passenger Side
STEP 27:
VV
Unfold and layout the Aerfoil Cover. Note the location of the large BLACKBOX logo on the Aerfoil Cover.
To help with orientation this logo marks the drivers side of the cover.
Turn and place the AerFoil face down so the inner groves are exposed. Unfold Bulk Heads [WW] and [XX]
and remove the pre-installed Joint Connector Bolt [YY] from the ends of the Bulk Heads. Insert the Bulk
Heads into the groove near the edge of the AerFoil Cover [VV] so the Bulk Head’s cut line faces the interior
of the carrier [Figure 38 & 39].
NOTE: The BlackBox Logo on the face of the cover indicates the drivers side of the Aerfoil Cover.
Bulkhead [WW] MUST be placed on the drivers side.
Re-Insert Joint Connector Bolts [YY] through the pre-installed Pin Nuts [ZZ] and tighten.
Cut Line
WW
XX
VV
YY
ZZ
WW
STEP 26
Remove backing and apply Reector Strips [UU] to the outer U-Tubes [U] on the
rear of the carrier as shown [Figure 38].
Install four (4) 1in Black End Caps [DD] into the open ends of the Frame Bars [EE]
[Figure 38]. UU
EE
DD
U
[Figure 37]
[Figure 38]
[Figure 39]
TOOL: 5/32 ALLEN WRENCH/SOCKET

PAGE 15 OF 21
NOTE: This step will be easiest if someone assists you.
Form the AerFoil Cover [VV] around the Bulk Heads [WW & XX] inserting the edges of Bulk Heads into groove
of cover as you go. Attach the remaining two corners with pre-installed Pin Nuts [ZZ] and Joint Connector Bolts
[YY] using the same method used in STEP 27 [Figure 40].
STEP 28 TOOL: 5/32” HEX WRENCH
YY
ZZ
VV
[Figure 40]
XXWW
NOTE: While Let’s Go Aero takes time to inspect and clean all
products before they leave our facility, some Plastic Shavings
may fall from AerFoil lid during the unpacking assembly process.
These are a normal result of the manufacturing process and are
knocked loose during shipment.
Latch Keeper
Adjustable Pull Latch
VV
STEP 29 TOOLS: 3/8” WRENCH, PHILLIPS SCREWDRIVER, DRILL, 1/4” BIT.
NOTE: This step will ne easiest is some assists you.
Place the AerFoil Lid on top of carrier bottom. You should be
able to engage the Adjustable Pull Latches pre-installed to
End Panel [LL] once the Lid is positioned properly [Figure 41].
NOTE: If the “catch” of the Pull Latch does not meet the Latch
Keepers pre-installed on Bulk Head [XX] the “catch” can be
raised by spinning the “catch” counter clockwise or vice versa
to be lowered.
[Figure 41]
XX

PAGE 16 OF 21
STEP 30 TOOLS: 7/16” WRENCHES
NOTE: This step will be
easiest if someone assists
you.
CAREFULLY, pivot the lid
open towards the drivers side
until the Hinges on the drivers
side of the box align [Figure
43].
Using one (1) 3.5in x 1/4in
Bolt [AAA] and one (1) 1/4in
x 20 Nylock Nut [BBB] on
each hinge, secure the hinges
together [Figure 42].
Once the hinges are secured, close the lid.
NOTE: This step will be easiest if someone assists you.
Carefully, lower and close the lid.
Join two (2) AerFoil Bands [CCC] together with one (1) Band Spring [DDD] at the ends with the
smallest holes. [Figure 46] Repeat for the remaining two (2) AerFoil Bands and Spring.
Lay the Band/Spring assembly over the AerFoil Cover [VV] by bending the assembly around the top
edge of the Aerfoil Cover with the padded side of the Bands placed against the Cover as shown.
Attached the Band/Spring assembly by starting at removing one (1) Joint Connector Bolt [YY] from
one corner of the Aerfoil Cover and then re-thread the Bolt through the larger hole at the end of the
AerFoil Band [CCC] and then into the carrier cover [Figure 44 & 45]. Repeat this step for the other
side of the carrier with the remaining Band/Spring assembly.
IMPORTANT: Remove and reattach each bolt ONE AT A TIME before moving to the next bolt.
STEP 31 TOOL: 5/32” HEX WRENCH
CCC
[Figure 44]
AAA
BBB
[Figure 42] [Figure 43]
CCC
DDD
YY
REMOVE &
REATTACH
[Figure 45]
[Figure 46]
Hinge
YY
CCC
YY

PAGE 17 OF 21
13.25in
13.25in
13.25in
13.25in
NOTE: Tip of the 7/8in Self-Tapping Screws [III] are self-drill-
ing as well. You may choose to power drive the screws with-
out pre-drilling if you have the tools and skill to do so.
Carefully, open the BlackBox lid. Starting from
the drivers side edge of the carrier (closest to
the hinges), measure 13.25in along each side
of the carrier tray edge. Mark these locations.
Place the closest edge of each Lift Plate
[EEE] at the 13.25in mark with the top of the
Lift Plate even with the top of the Side Rail [T]
[Figure 47 & 48].
Using the Lift Plate [EEE] as a guide, center
punch an indentation or create mark at each
hole center. Using two (2) 7/8in Self Tapping
Screws [III] and two (2) 1/4” Split Ring
Washer [MMM] for each plate. Secure the Lift
Plates to the carrier rail as shown [Figure 49].
NOTE: Each Lift Arm [FFF] is
marked A or B. Lift Arm “B” must
be installed on the side of the carrier
that is closest to the vehicle. “Side
A” must be installed on the side of
the carrier furthest from the vehicle
[Figure 50].
Using the angled plates on each
Lift Arm [FFF], attach the upper
lid portion of both Lift Arms to the
open holes on the side of the carrier
lid using two (2) 10-24 x 1 Screws
[JJJ]and one (1) 10-24 Nylock Nut
[LLL] on each Lift Arm as shown
[Figure 51].
Next, mount the lower section of
each Lift Arm [FFF]to the Lift Plate
[EEE] using two (2) 5/16in Washers
[KKK] and one (1) 3/8in Nylock
Nut [HHH] for each Arm as shown
[Figure 52].
STEP 31
STEP 31
TOOL: 5/16IN SOCKET
TOOL: PHILIPS SCREW DRIVERS, 3/8 & 9/16 SOCKET OR WRENCH
EEE
EEE
MMM
[Figure 47]
[Figure 49]
[Figure 48]
[Figure 52]
[Figure 50]
T
T
III
[Figure 51]
FFFb
FFF
FFF
JJJ
LLL
FFFa
KKK
HHH
EEE

PAGE 18 OF 21
Snap the Gas Shocks
[GGG] onto the ball studs
of both Lift Arms [FFF].
NOTE: The thicker portion
of the Gas Shock [GGG]
must be installed onto the
side of the Lift Arm [FFF]
that is attached to the Lift
Plate [EEE] [Figure 53 &
54].
NOTE: If you are having
trouble getting the Gas
Shock [GGG] to “snap”
onto the ball stud, you may
need to adjust/loosen the
clip on the back of each gas
shock head with a at head
screw driver.
Remove the loose velcro patches from the Support Bands [NNN]. One at a time, remove the plastic lm from
the back of the velcro patches and apply the velcro patches as shown to the inside edge of the Aerfoil Cover
Sheet [VV]evenly spaced in three sections across the lid as shown. [Figure 55].
Insert the Support Bands [NNN] into the lid of the carrier attaching each end to velcro placed on the inside of
the Aerfoil Cover. The curve of the support band should match the inner curve of the carrier lid [Figure 56].
STEP 31
STEP 31
TOOL: FLAT HEAD SCREW DRIVER
TOOL: 5/32” HEX WRENCH
GGG
NNN
NNN
NNN
EEE
FFF
VV
Ball Stud
Clip
[Figure 53]
[Figure 55]
[Figure 54]
[Figure 56]
Velcro Velcro
VV

PAGE 19 OF 21
Never “throw” or “slam” the BlackBox lid open or closed. The lid should always be opened and closed slowly and with
care. Failure to follow proper lid care may result in damage to carrier, damage to property, bodily injury or death.
WARNING:
Never begin transit without ensuring that BOTH
quick release latches are fully engaged.
WARNING:
Always operate the BlackBox lid from the
passenger side of the vehicle.
Closing: When closing the BlackBox, gently
(but rmly) pull the long Fabric Strap towards the
passenger side of the carrier to pull the lid down.
Once the Handle attached to the passenger side
bulkhead is with-in reach, grab the Handle and
continue to close the lid using the Handle.
Engage both Quick Release Latches located on the
passenger side to latch the lid in place [Figure 58].
Optional: Run a pad-lock (customer provided) threw
each Quick Release Latch to lock the carrier.
Opening: When opening the BlackBox, release both
Quick Release Latches located on the passenger side. Using the handle lift (don’t throw), the lid until the gas
shocks begin to engage. Grab the Fabric Strap from inside the carrier to slow down the lid and ensure the Lid
doesn’t open to quickly. Slowly open the Lid until it rests in the upright/open position.
[Figure 58]
P
U
L
L
CAULK
TOOL: BLACK WATER-PROOF SILICONE CAULK
[Figure 57]
OPTIONAL TIP!
OPERATION: Opening & Closing
For a complete weather seal,
it is recommended to caulk all
gaps and edges with a black
Silicone Water-proof Caulk
[Figure 57].

PAGE 20 OF 21
OPERATION: Opening & Closing
Slide-out: Remove the Retainer Clip [B] and Hand-Tighten Pin [D] and set aside [Figure 59].
Standing on the side of the carrier that is furthest away from the vehicle, gripping from the underside of the
carrier, pull the carrier horizontally away from the vehicle untill the Safety Cable is fully extended.
Slide-in: Standing on the side of the carrier that is furthest away from the vehicle, gripping from metal tray,
push the carrier back towards the vehicle until the holes for the Hand-Tighten Pin [D] re-align.
Re-insert and fully thread the Hand-Tighten Pin [D]. Secure with Retainer Clip [B].
Do not push or pull on the carrier lid. Pushing or Pulling on the carrier lid during slide-out/in operation may cause
warping of the lid over time. Failure to follow proper lid care may result in damage to carrier, damage to property,
bodily injury or death.
Always ensure the Hand-Tighten Silent Hitch Pin is fully threaded and secured with retainer clip (or a Lets Go Aero
Hitch Pin Lock) before transit. Failure to the Hand-Tighten Pin may result in damage to carrier, damage to property,
bodily injury or death.
WARNING:
WARNING:
D
B
[Figure 59]