LIMITLESS VAN SAFARI User manual

Link to limitlessvan.com
LIMITLESS VAN LLC STRONGLY RECOMMENDS PROFESSIONAL INSTALLATION OF AFTERMARKET ACCESSORIES TO
YOUR VEHICLE. IMPROPER INSTALLATION COULD RESULT IN AN AUTOMOBILE ACCIDENT AND COULD CAUSE
SERIOUS INJURIES OR DEATH. YOU MUST ENSURE THE PERSON(S) INSTALLING THE PRODUCT READ, UNDERSTAND,
AND FOLLOW ALL INSTRUCTIONS AND WARNINGS BEFORE BEGINNING THE INSTALLATION. THE RESPONSIBILITY TO
CORRECTLY INSTALL LIMITLESS VAN PRODUCTS IS YOURS AND MUST BE TAKEN SERIOUSLY. LIMITLESS VAN LLC WILL
NOT BE HELD LIABLE OR RESPONSIBLE FOR DAMAGES OR PERSONAL INJURIES RESULTING FROM THE USE OF OUR
PRODUCTS. MOREOVER, THE REGULAR INSPECTION AND MAINTENANCE OF AFTERMARKET PRODUCTS IS YOUR
RESPONSIBILITY.
PLEASE READ BEFORE INSTALLATION
• ALWAYS INSPECT YOUR PRODUCTS UPON ARRIVAL FOR
SHIPPING DAMAGE OR MISSING PARTS
• REPORT MISSING OR DAMAGED PIECES TO OUR SUPPORT
TEAM BEFORE BEGINNING THE INSTALLATION

INCLUDED HARDWAREINCLUDED HARDWARE
MATERIALS REQUIREDMATERIALS REQUIRED
-1/4-20 X 3/4 HEX SCREWS
-1/4 CAGE NUTS
-5/16 X 1 1/8 HEX BOLT
-5/16 WASHERS
-5/16 LOCK NUTS
-1/4 20 X 11/8 SETSCREWS
-1/4 RUBBER WASHERS
-1/4-20 X 3/4 SCREWS
-1/4 WASHER
-5/16 BOLTS
-M8 BOLTS
-M8 WASHER
REQUIRED
-TWO PEOPLE
-WINDOW WELD SEALANT
-STEP LADDER
-HAND SCREWDRIVER
-RATCHET AND 5/16TH SOCKET
-5/32ND ALLEN WRENCH
-CHANNEL LOCKS OR PLIERS
-CAULKING GUN
60
60
20
40
20
32
20
8
60
20
10
10
RECOMMENDED
-POWER DRILL
-1/4” METAL DRILL BIT
-M8 TAP
-THREADLOCKER
THREADLOCKER IS RECOMMENDED ON
ALL FASTENERS (LOCTITE BLUE 242).
*148” Wheelbase with mid-roof shown

INSTALLATIONINSTALLATION
1
2
-START WITH A CLEAN ROOF FREE OF DEBRIS
-LOCATE THE EIGHT FACTORY MOUNTING
LOCATIONS ON THE ROOF
-REMOVE THE RUBBER PLUGS FROM EACH THREAD-
ED HOLE
-CLEAN ADHESIVE FROM THE PERIMETER OF THE
HOLE
-CHECK THE THREADS IN EACH LOCATION
AS THERE IS A HIGH PROBABILITY OF FACTORY
OVERSPRAY.
-NOTE-
THE ROOF PANEL MIGHT
BE MISALIGNED TO THE
THREADED HOLES FROM THE
FACTORY. THIS WILL REQUIRE
YOU TO DRILL OUT THE ROOF
PANEL DIRECTLY ABOVE THE
THREADED INSERT.
-THE ROOF RACK ASSEMBLY STARTS ON THE GROUND BY BUILDING THE LEFT
AND RIGHT RAILS
-SLIDE THE RAILS TOGETHER ENSURING THE SMALLER DIAMETER TUBE IS
COMPLETELY COVERED BY THE LARGER DIAMETER TUBE BEFORE THREADING IN
THE SET SCREWS
-AFTER THREADING THE SET SCREWS INTO THE TUBE SECTIONS INSERT THE 1/4
20 X 3/4” HEX BOLTS INTO THE RAIL AND ATTACH WITH NYLON LOCK NUTS
*DO NOT REMOVE THE PLUGS OUTSIDE OF THE EIGHT
INSET MOUNTING LOCATIONS, THOSE ARE NOT REQUIRED FOR INSTALLATION

3
4
-ONCE THE ROOF RAILS HAVE BEEN ASSEMBLED, THE CAGE NUTS WILL BE
INSTALLED INTO THE SQUARE HOLES RUNNING THE LENGTH OF THE ASSEMBLY
-USE A PAIR OF CHANNEL LOCKS OR PLIERS TO SQUEEZE THE TABS ON THE
CAGE NUTS AS YOU PUSH THEM INTO THE HOLES.
-DURING THIS STEP YOU CAN OPT TO PREEMPTIVELY INSTALL THE CAGE NUTS
INTO THE OTHER RAIL SECTIONS SUCH AS THE FRONT AND REAR RAILS
-STEP FOUR IS ONLY APPLICABLE TO RACKS OPTIONED WITH ROOF VENT
CUT OUT(S)
-LOCATE AND LAY OUT THE FOUR VENT SURROUND PIECES ON THE
GROUND
-SLOT THE TUBULAR BARS INTO THE SIDE OF THE DECKING WITH THE
PRE DRILLED HOLES FACING UP. MAKE SURE THE HOLES RUNNING THE
LENGTH OF THE CROSSBARS FACE INWARDS TOWARDS THE MIDDLE OF
THE VENT SURROUND
-ATTACH THE TUBULAR BARS TO THE DECKING WITH THE INCLUDED 1/4”
COUTERSINK HARDWARE

5
6
-APPLY A GENEROUS AMOUNT OF SEALANT TO THE
CIRCUMFERENCE OF EACH THREADED INSERT ON THE ROOF
-PLACE THE STAND-OFFS ONTO THE SEALANT AND PLACE THE HOLE
IN THE STAND-OFF BASE DIRECTLY OVER THE THREADED INSERT
-THREAD THE INCLUDED M8 1/4” BOLTS WITH RUBBER AND STEEL
WASHERS INTO THE ROOF THROUGH THE STAND-OFF,
HAND TIGHTEN ONLY.
-WITH THE ASSISTANCE OF A SECOND PERSON, LIFT ONE RAIL AT
A TIME AND SET ON TOP OF THE STAND OFFS
-SECURE THE RAIL TO THE FURTHEST REAR STAND-OFF FIRST BY
APPLYING THE 5/16” HEX BOLT WITH INCLUDED WASHER AND
LOCK NUT, HAND TIGHTEN ONLY
-FASTEN THE FURTHEST FRONT RAIL ON ITS STAND-OFF BEFORE
INSTALLING THE REST OF THE HARDWARE ALL THE WAY DOWN THE
RAIL, THEN TORQUE DOWN ALL RAIL HARDWARE

7
8
-LOCATE SPOTS ALONG YOUR RAILS WITH AT LEAST 18 INCHES OF
SPACE ON EITHER SIDE OF YOUR ROOF VENT(S)
-START AT THE REAR OF YOUR VAN BY SLOTTING ONE PIECE OF
ALUMINUM DECKING OVER THE TRACKS LOCATED ON THE LEFT AND
RIGHT RAILS
-SLOT A TOTAL OF FOUR ALUMINUM DECKING PIECES SPACED OUT,
BEING MINDFUL TO AVOID THE PORTIONS OF THE ROOF WHERE YOUR
ROOF VENT OR AC ACCESSORIES WILL BE
-AFTER FOUR SECTIONS HAVE BEEN SLOTTED INTO PLACE, USE THE
INCLUDED 1/4” 20 PHILLIPS/ HEX HARDWARE TO SECURE THE DECKING
-WITH THE HELP OF A FRIEND, SET YOUR ASSEMBLED VENT SURROUND
OVER YOUR ROOF VENT
-SLIDE YOUR VENT SURROUND FORWARD AND BACKWARD UNTIL THE
OPENING SITS EVENLY OVER THE VENT
-MAKE SURE NO PART OF THE RACK SITS OVER YOUR VENT BEFORE
ATTEMPTING TO OPEN THE VENT

9
10
-SLIDE THE REAR OF THE RACK ONTO THE LEFT AND RIGHT RAILS
AND FASTEN WITH THE INCLUDED 1/4” BOLT WITH WASHERS
-THREAD THE INCLUDED SET SCREWS INTO THE THREADED HOLES
ON THE TUBULAR SECTION OF THE RACK
-SLIDE THE LOWER FRONT RADIUS INTO THE FRONT OF THE
RACK AND FASTEN WITH INCLUDED SET SCREWS
-TORQUE DOWN THE RACK STANDOFFS WITH A RATCHET
-ATTACH THE REST OF THE LONG ALUMINUM DECKING PIECES
TO THE LEFT AND RIGHT RAILS AND FASTEN WITH THE INCLUDED
HARDWARE
-ATTACH THE SHORT DECKING PIECES TO THE SIDES OF THE VENT
SURROUND AND THE RACK RAILS
-CHECK ALL THE DECKING HARDWARE AND ENSURE A TIGHT FIT

LIMITLESS VAN PRODUCTS ARE
PROUDLY MADE IN THE USA.
FOR ANY QUESTIONS REGARDING
INSTALLATION OR REPLACEMENT PARTS CONTACT US:
[phone]
[email protected]
LIMITLESS_VAN
FACEBOOK.COM/LIMITLESS VAN
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