Fiberglass Canopy Roof Track Installation - Cascade Rack

Welcome to Cascade Rack’s how to on install track on a Fiberglass canopy.
Today we’ll do a detailed walk through on how to install track on a fiberglass canopy in order to attach a set of Rhino Rack Crossbars.
The parts needed for the track installation will generally come in kit that will include the two roof top track sections, enough bolts and nuts for installing the track utilizing every other hole, four end caps, and RTV sealant for sealing the holes.
The first thing you will need is your choice in crossbar setup. We generally go with Rhino Rack, Which is what you’ll see here. 2 Vortex Bars, And a Pack of RLT600s.
Next, we have the Track. We go with Thule, It seems to work the best while keeping a low profile. here you see tracks, endcaps, nylon washers, Capnuts, and bolts
Finally, The tools. Tape Measure, Flexible tape measure, wax pen, Sharpie, center hole punch, Drill, 1/8 inch as well as a ¼ ich bit, silicone sealant, electric wrench, paired with the bit you need for the previously mentioned bolts.
Once we Decide on the length of track that we need, It gets a chop by the bandsaw.
We then place the feet at the width that we want the track to be on the canopy
Placing the bases about an inch and a half from the ends of the track will aid us in assuring the tracks are parallel
Keep in mind, youll need square plates that fit the track you’ve chosen. We use Yakima A plates
For the Thule track
Here we are deciding the front placement for the track by measuring off of points on the canopy. This process can vary between different shells, so just be sure each side is the same.
Time to attach the crossbars and square up the tracks, and line up the front edge with the point we just marked
Time for the most important part, assuring the tracks are perfectly even on top of the canopy. We do this by measuring the edges of he track, just below each foot, to the very bottom edge of the shell. Triple check yourself just to make sure. This is permanent
Once we’ve determined its squared up, its time to mark the holes. Mark every other point, including the front and rearmost. Do the same on the other side.
Now that our drill points are marked, remove the track to expose your sharpie dots. Use the center hole punch and click it directly in the center of each point. This keeps your drill bit from walking and improves accuracy.
And now the fun part. Start with your 1/8 drill bit and drill through at each point. If your canopy is double layered, be sure to go through both layers, keeping the drill at a 90 degree angle to the shell.
Next take the ¼ and enlarge the holes you just made. This will clear up enough space for your bolts to slide through.
Lets seal them up. Starting at the center of the hole, apply the sealant and work out in a swirling motion, covering up the edges and ending back towards the center. Place nylon washers on top of each blob of sealant
This part can be a bit tricky, we’ve found that starting from one end, and slowly working back produces best results. Taking your time, make sure each bolt is lined up with its hole before moving on to the next. Be careful not to smear your sealant.
Time to tighten it up. With one person operating the wrench from the top and another holding the capnuts in the inside of the canopy, work your way back….. No need to overtighten, we usually go until the electric stops and give it another quarter to a half turn.
Now that the track is complete, adjust the bases to your desired bar spread. We usually go for 32”, that seems to work great for most applications.
If you did everything correctly and the tracks are square, the crossbars you previously measured should fight right in.
Go ahead and double check the overhang, just to make sure you’re even on each side.
Pop on the finishing touches, and were good to go
There you have it, Perfect track and crossbars on your canopy.