fairing installations
bolt on fairings
Use the supplied pipe clamps to wrap around the top bar. Insert the 1/4-20 bolt through the fairing, then through both sides of the pipe clamp, securing with a washer, lock washer, and nut. Get all 4 of the clamps finger tight, leaving the fairing flipped-up for the moment. Add optional clamps to the lower Expo bar of the rack, if desired, evenly spaced. These can aid in reducing vibration. Alternatively, rubber pads can be added to the back side of the fairing, to go between the fairing and rack.
snap-on fairings
Snap-on fairings are easy to install, particularly with the new plastic clips released in 2020. Insert the 1/4-20 bolts through the fairing, and through the plastic clip, then add the flare nut. Leave only finger tight then install the fairing to the rack. With one hand slide the clips to create interference, into the bar they are aligned with, then tighten the bolts to secure them in place. Experiment with adjusting the clip tension to achieve the desired resistance with the fairing removal, and ability to hold the fairing in place.
Once the plastic clips are secured in place, to remove the fairing simply pull out one side of the fairing, then push the fairing outward from behind. To install, align the bottom clips to the lower bar, then push down on the top clip as you push the fairing into place. Allow the fairing to flex for easier installation/removal. If there is any vibration, use rubber pads on the back side of the fairing to create softer contact areas between the fairing and rack.
Video of the snap on fairing install
Adjusting the gap between fairing and roof
Getting the gap just right can be a challenge sometimes, for traditionally shaped fairings, you want about 1/4” between the fairing and roof, to insure the fairing doesn’t touch the paint. Here are some tips that apply to all roof racks:
Raise the height of the front tower, to tip the rack up in front slightly. On roof channel racks, this means removing that small center adjustment bolt, and pushing the rack up even further.
Adjust the position of the rack- most applicable to rain gutter racks, but you can slide the rack forward/backward to get desired clearance.
Trim the fairing- you can make a small chamfer to the inside edge of the fairing with a utility knife, which may enough to get the clearance you need. You can also cut the fairing with a band saw or jig saw if you want to get more into modifications, it’s ABS plastic so fairly easy to work with.
On flat racks, where the fairing is bolted to angled light tabs, you can make slight adjustments within the light tabs themselves, sliding the bolts up and down. You can also put washers in between the fairing and tabs on the center bolts, which will cause the fairing to bend slightly, and gain more clearance in the center, as well as gain a little stiffness to help prevent deflection from the oncoming wind.
Modifying your fairing
It is inevitable that at some point the need will present itself to turn a bolt-on fairing into a snap-on, or a snap-on to a bolt on, or convert from metal to plastic clips. Well rest easy, as it’s just a piece of ABS plastic and one of the easiest things there is to modify. Below are some pictures and tips for how to add more holes into your fairing.
The hole pattern for the plastic clips is 7/8” x 2”. That is for a rack with either version of the light bar drop down, which creates a 2.75” gap between the main rack hoop and Expo bar. If you want to install a snap-on fairing to a rack without the larger gap, then your gap should measure 1.75”, and your hole pattern is 7/8” x 1”.
The top holes for the plastic clips begin 1” down from the top edge of the fairing.
One trick for the plastic clips is to use an actual clip as a drill guide. Just measure down 1” and 3” from the top edge of the fairing, drill your first hole, then bolt a clip to it.. then drill through the slot on the other side of the clip for the second hole.
If you are adding holes for a 1” pipe clamp for a bolt-on or snap-on fairing, the top hole is 1.25” down from the top edge of the fairing.
The drill size is 1/4”. If you miss a little, just put the drill back in and “waller” it out a little.. don’t worry, the bolt head will cover it.
Before you drill, first verify the location you are drilling will not interfere with a rack post, or other obstruction. Use a utility knife to mark your hole locations, making your marks on the smooth side of the fairing. Use a carpenter’s square to insure your hole pattern is aligned well with the fairing edge.
