Cut the channel to the cut list and deburr the ends. Slotted channel: slots facing up on the sides and cross beams.
Build the halo on the ground. Push a corner onto each end of the two side channels and the two end cross members. Fit the angle bracket inside each corner with spring nuts and M8 bolts, finger-tight.
Add the cross beams. A channel tee on each end, three spring nuts and bolts per tee into the side channels, finger-tight, positioned as your plan shows.
Square it up. Measure corner to corner both ways; when the diagonals match, tighten every bracket and tee.
Prepare the roof. Clean each fixing point. Fit the threaded roof inserts if your van does not already have them, and put a sealing washer on every point.
Fit the rack. With help, lift the frame onto the roof. At each point sit the spacer from your plan, then the bolt of the listed length with its penny washer through the channel floor into the insert. Tighten evenly, snug rather than crushing the spacer.
Check. Sight along each side channel: straight, with every spacer bearing on the roof. Re-check all bolts after your first drive and again a week later.
Need a hand?
Stuck on a step, or something does not fit the way the plan shows? Send us a photo and your order number and we will sort it.
