Let's Go Aero BLACK BOX Assembly, Installation And Operation Instructions - User Manual

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PAGE 1 OF 14

BLACK BOX

Slide-Out Enclosed Cargo Carrier System

Set Item Product

BBOXManual-042117Rev

BlACK BOX SYSTEM - ASSEMBLY, INSTALLATION, AND OPERATION INSTRUCTIONS:

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: SUPPORT@LETSGOAERO.COM

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.

FlatPipe™ Spine Assembly & Installation on Hitch...........................................

Safe Use & Operation ........................................................................................

Rack Parts & Assembly ...................................................................................... 4
AerFoil Lid Parts & Assembly ............................................................................. 11
Warranty & Registration .....................................................................................

Description

Page

PAGE 2 OF 14

FLATPIPE™ SPINE ASSEMBLY AND INSTALLATION

Qty. Description

A 1

FlatPipe™ Spine

B 2

Retainer Clip

C 1 5/8” Silent Hitch Pin

D 1

5/8” Silent Hitch Pin

(hand-tighten version)

E 1 5/8” Lock Washer

F 1 5/8” Plastic Bushing

G 2 5/8” Spring Nut

H 2 End Cap, 2” Square

J 1

Wax

K 2

Rubber Bumper

L 1 5/8” Flat Washer

The Spine shank end contains two mounting holes. The ideal hole to use is the second hole in from the end. If the
shank bottoms out inside the receiver hitch, or if you need maximum clearance for a tailgate, use the first hole in
from the end.

NOTE: For proper cargo carrier balance, there is a 3° pitch on the Flat Pipe. Be
sure when installing your shank into the receiver hitch that the shank is right side
up and that the 3° faces upward.

FIRST

SECOND

STEP 1

Install two spring nuts [G] as shown.

STEP 2

REQUIRED TOOL: 7/8” WRENCH

Slide the shank end of the Spine [A] into the receiver hitch aligning the mounting hole with the hole in the re-
ceiver hitch. Attach with Silent Hitch Pin and a 5/8” Lock Washer [C,E] by threading the Pin into the Spring Nut
[G]. Tighten (30 ft.lbs. torque)and attach Pin Clip [B].

INSERT INTO VEHICLE

HITCH RECEIVER

Hitch Receiver

Shank End

3° Pitch

Shank End

PAGE 3 OF 14

STEP 3

Apply Wax [J] by rubbing the Wax block on all four sides of both tubes. Install two rubber bumpers [K] (one
onto each fixed tube). The remaining hand-tighten Silent Hitch Pin, Bushing and Retainer Clip [D,F,G] will be
used to secure the Black Box Rack to the FlatPipe Spine in a later step.

End Caps [Factory Installed]

Rubber Bumpers

Wax

Vehicle and Hitch Receiver Compliance

This Cargo Carrier fits 2" size hitch receivers and is rated for a Class II tow capability or higher. Before using this

product, consult your vehicle and hitch receiver owner manual(s) for details on your tow and tongue weight parameters.

Be sure that they are compatible with Black Box’s weight specifications.

Tongue Weight Compliance

The Black Box and its cargo create a combined weight that creates direct downward pressure on the hitch receiver’s

tongue. This downward pressure is the tongue weight. Tongue weight is one of the two critical weight rating factors of

your tow rating’s classification. Never exceed your vehicle and hitch receiver’s tongue weight specification.

Black Box Weight and Load Parameters

The Black Box weights 160 lbs empty. To determine your available load weight in accordance with your vehicle

and hitch receiver’s tongue weight rating, subtract Black Box’s weight from your identified tongue weight rating. The

difference represents your vehicle and hitch receiver’s available load weight. The Black Box is rated for up to 300 lbs of

cargo payload weight. Position heaviest cargo in the center of the carrier and lighter cargo to the outside perimeter

About Slide Out & Clearance Adjustment Of Carrier

To telescope the Black Box, remove the Hand Tighten Silent Hitch Pin® from the slide out pin hole. Verify that the

Safety Cable is secured and then slide the frame to the rear. For added clearance, adjust the position of the Hat

Brackets along the Frame’s Female Slide Tubes. Be sure to adhere to NO USE AREA distance of 3.5 inches rearward

from Spine’s vertical plate along the frame tubes.

SAFE USE OPERATION

Be sure to follow these guidelines to prevent possible hazards from misuse.

TIP: Secure your gear during transit, contents may shift causing damage to gear and/or cargo carrier. It is user

responsibility to properly secure cargo. Optional tie down items are available at Let’s Go Aero for purchase.

PAGE 4 OF 14

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).

NOTE: End Tubes [X] and excess Square End Caps [EE] are for open rack assembly only.
For Black Box Enclosed Cargo Carrier you may discard these pieces or save for open rack

use. See GearCage Rack assembly manual for open rack assembly.

RACK PARTS LIST & ASSEMBLY OVERVIEW

2
2
4
8
8
8
1
2

FEMALE TUBES
FRAME ANGLES
HAT BRACKETS
5/16 CARRIAGE BOLTS
5/16 WASHERS
5/16 NUTS
SAFETY CABLE WITH QUICK LINK
END CAPS WITH REFLECTORS, 2-1/4”

U
V

X
Y

AA
BB
CC
DD

4
3
2
2

24
16

8
2
4
2
2
1
1
4
4

U-TUBE
FLOOR PANEL
SIDE TUBE
END TUBE (OPEN RACK ONLY)
JOINT CONNECTOR BOLT 2.5”
M6 X 15 SOCKET HEAD BOLT
M6 WASHER
M6 NYLOCK NUT
SOCKET HEAD BOLT 1.5”
PIN NUT
SQUARE END CAPS
CROSS TUBE
PLUG
SOCKET HEAD BOLT 1.6
SIDE PANEL
END PANEL WITH HINGES
END PANEL WITH PULL LATCHES
1/4-20 X 3/4 BOLT
K-LATH SELF TAPPING SCREW

XX
YY

AAA
BBB
CCC
DDD

EEE

FFF

GGG

HHH

III

JJJ

KKK

LLL

1
1
1

1
4
8
4
4
2
4

2
2
2
2

POLYPRO COVER SHEET
BULKHEAD
BULK HEAD WITH LATCH KEEPER
.75” WASHER
BALANCE CABLE
1/4-20 NYLOCK NUT
HANDLE
1/4-20 JOINT SOCKET HEAD BOLT
1/4-20 X 1.25 BOLT
1-4-20 PIN NUT (BLACK)
43” AERFOIL BAND
BAND SPRING
.3” X 1 WASHER
1/4 X 1 FENDER WASHER
1/4-20 X 1.5 BOLT
10-24 X 1.25 PHILLIPS SCREW
10-24 NYLOCK NUT
3/16 X 1 FENDER WASHER

TWINTUBE FRAME MOUNT

RACK & SIDE PANEL

AERFOIL LID (Black Box Cover)

QTY. DESCRIPTION

2
1
2
2
2
2
2

LED LIGHTS
WIRE HARNESS
LED LICENSE PLATE BRACKET
LED MOUNT BRACKET
6mm HEX BOLT
6mm NYLON BOLT
6mm WASHER

LIGHT KIT

QTY. DESCRIPTION

Tools Needed:

9/16" Wrench and Socket
7/16" Wrench and Socket
5/32” Hex Key

3/16” Hex Key
Center Punch
Drill and Drill Bits

PAGE 5 OF 14

FLAT PIPE

FRAME MOUNTING

PLATFORM

PAGE 6 OF 14

FLAT PIPE

FRAME

MOUNT

Align to Flat

Pipe Spine

Attach the Flat Pipe Frame Mount to each Cross Tube [FF] using a 1.6” Socket Head Bolt, M6 Washer and a
M6 Nylock Nut [HH, AA, BB]. Hand tighten only at this time.

STEP 1

STEP 2

Slide the Female Tubes [M] over
FlatPipe Spine [A]. NOTE: The
holes at the end of the Spine and
the Females Tubes must line up for
proper assembly. Using 5/16 Carriage
Bolts, 5/16 Washers, and 5/16 Nuts
[P, Q, R] attach the Frame Angles
[N] and the Hat Brackets [O] to the
Female Tubes. The vertical portions
of the frames angles should face the
exterior of the carrier and the Hat
Brackets bolting to the frame angles
from underneath the females tubes
and spine. Install the Safety Cable [S]
by placing the looped end (the side
without the Quick Link) in between
the Hat Bracket and Frame Angle
(located closest to the vehicle, on
the passenger side, using the side
of the Hat Bracket that faces
the interior of the Spine).
Hand Tighten all connections
at this time. Install End Caps
with Reflectors [T] at the ends of the
exposed Female Tubes.

AA
BB

PAGE 7 OF 14

STEP 3: Using a M6 Washer and a M6 Nylock
Nut [AA, BB] with a 2.5” Joint Connector Bolt
[Y] join two (2) Floor Panels [V] (excluding the
third, center Floor Panel which will be attached
in the next step), four (4) U-Tubes [U], to
the assembled Cross Tubes [FF] and Frame
Angles [N] of the Flat Pipe Platform. Continue
to hand tighten only at this time.

Press four End Caps [EE] into ends of each
Cross Tube [FF].

FLAT PIPE

FRAME

MOUNT

Place the last Floor Panel [V] in the center on top of the U-Tubes [U]. Use M6 x 15 Socket Head Bolts, M6
Washers, & M6 Nylock Nuts [Z, AA, BB] at each of the six (6) locations on the underside of the panel to secure
the center to the outside panels. Hand tighten only at this time.

STEP 3

STEP 4

AA
BB

PAGE 8 OF 14

Using a 1.5” Socket Head Bolt [CC] and Pin Nut
[DD] on the two holes at the ends of the tubes
only, connect the Side Tubes [W] and Side
Panels [II] to the rack frame by dropping the
Socket Head Bolt through the top of the Side
Tube down through the Side Panel [Figure 1].

NOTE: There are two holes of different sizes
at each end of the side tubes, the larger holes
should face upwards to allow the head of the
bolt pass through the top and then rest on the
smaller hole on the bottom of the interior of the
tube [Figure 2].

Finish connecting the ends Side Panels and
Tubes to the U-Tubes [U] by placing a Pin Nut
[DD] Horizontally through the holes at the end of
the U-Tube and then securing the Socket Head
Bolt [CC] through the treading in the Pin Nut.
Cap these locations (4) with provided Rubber
Plugs [GG].

NOTE: For an easier match the Pin Nut is
designed with a flat head slot to illustrate the
direction of the internal thread. The knotted end
should rest on the edge of the U-Tubes [U]
hole as shown [Figure 3].

Connect the center portions of the Side
Tubes [W] and Panels [II] with 1.5” Joint
Connector Bolts [Y] and Pin Nuts [DD]
(These bolts will NOT pass through the
Side Tubes as the Socket Head Bolts [CC]
did at the ends of the tube).

Hand tighten only at this time.

[Figure 3]

[Figure 1]

Large Hole

Small Hole

[Figure 2]

STEP 5

PAGE 9 OF 14

With the Side Tubes and End Tubes in place. Un-bolt and remove
the two (2) 2.5” Joint Connector Bolts [Y] at each end of the rack
allowing the bottom lip of the End Panels [JJ] and [KK] to slip
between the Cross Tubes [FF] and U-Tubes [U] [Figure 3]. The
End Panel [JJ] that includes Hinge hardware must be installed on
the Drivers Side of the Vehicle. With the holes aligned, re-insert the
Joint Connector Bolts [Y] [Figure 4].

Using two (2) Joint Connector Bolts [Y] and two (2) Pin Nuts [DD]
on each side, connect the End Panels [JJ] and [KK] to the Side
Tubes [W] by passing the Bolt through over-hanging edge to the
base to of the End Panel and then threading the bolt through the Pin Nut on
the interior of the Side Tube. Secure and tighten all hardware from
previous steps of the Rack and Side Panel installation.

Locate two 3/16” dia. holes in each end panel.
Center punch an indentation at each hole
center. Drill 1/8” dia. holes into
end tube and u-shaped
tube. Insert and
tighten four self-tap
screws [C].

[Before]

[Figure 3]

[Figure 4]

STEP 6

WARNING:

Never operate the vehicle without the hand-tighten Silent Hitch Pin

properly engaged to prevent the carrier from sliding while in transit.

Failure to do so may result in bodily injury and property damage.

NOTE: Tip of screws [C] 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.

Insert the Silent Hitch Pin With Handle [D] and
Plastic Bushing [F] on the forked end of the Spine
[A] containing the second Spring Nut [G]
inside. The Pin should be inserted so
that it passes through the block portion
of the Spring Nut first and then exiting through the
spring. Tighten firmly to engage threading and apply
Retainer Clip [B] as shown.

Apply the 2-1/4” End Caps [T] with
Reflectors to the exposed end of the Spine
[A] using a Rubber Mallet.

Insert the second Spring Nut [G] into the forked end of the Spine [A] (customer choice of side, only one side is
needed) [Figure 5].

STEP 7

STEP 8

[Figure 4]

CUSTOMER CHOICE OF SIDE

PAGE 10 OF 14

Un-Bolt LED Light Hardware supplied on the LED
Lights [NN] and then reattach onto LED Mount
Bracket [QQ]. For the drivers side of the vehicle
only, also include License Plate Brackets [PP] as
shown. [See Drivers Side Illustration]
Use 6 mm Hex Bolts [RR], 6 mm Nylon Nuts [SS],
and 6 mm Washer [TT] to install License Plate
(Customer Supplied License Plate Not Included)
onto License Plate Brackets [PP] as shown.
On the side of the rack furthest away from the
vehicle, use 1/4-20 X 3/4 Bolts [LL], .75” Washers
[XX] and 1/4-20 Nylock Nuts [ZZ] to install LED
Light Brackets [QQ] with mounted hardware and
LED Lights [NN] onto the Rack through the Side
Panel [II] and Floor Panel [V]. On the drivers side
only, include one Balance Cable [YY] loop end
between the LED Mount Bracket [QQ] and the .75”
Washer [XX]. [See Drivers Side Illustration]
On the other side of the rack on the side closest to the
vehicle (where the LED lights have not been installed),
secure the Side Panels [II] to Floor Panels [V] using
1/4-20 X 3/4 Bolts [LL], .75” Washers [XX] and 1/4-20
Nylock Nuts [ZZ] in the same manor excluding the
LED lights. The second Balance Cable [YY] should
also be included between the Side Panel and Washer
on the drivers side only.
Connect LED Lighting to the Wire Harness [OO] (not
shown) with the yellow wire connected to the drivers
side and the Green Wire connected to the passenger
side of the vehicle. Weave Wire Harness through the
underside of the Black Box Rack to prevent wire drag.
Connect the Wire harness to the Vehicle Trailer Light
Connection on rear of the Vehicle.

The Safety Cable prevents the Black Box rack from sliding off the Spine when telescoped. The rack may be slide out

when parked for vehicle hatch access only. Never move the vehicle while the carrier is slid out. Failure to engage the

Safety Cable may result in bodily injury and property damage.

Optional Safety

Cable Position

WARNING:

Connect the Quick Link Side of the Safety Cable
[S] to one of the available hole positions located
on the frame of the Flat Pipe Spine [A].

NOTE: The hole location furthest from the vehicle
is recommended for maximum slide out.

STEP 9

REQUIRED TOOLS:

CUSTOMER SUPPLIED

LICENSE PLATE

(NOT INLCUDED)

CUSTOMER SUPPLIED

LICENSE PLATE

(NOT INLCUDED)

CUSTOMER SUPPLIED

LICENSE PLATE

(NOT INLCUDED)

STEP 10

WARNING:

DO NOT ALLOW HAT

BRACKETS [O] TO

OVERLAP WARNING

LABEL ON FEMALE TUBE.

FAILURE TO PROPERLY CONNECT WIRES TO THE

WIRE HARNESS WILL RESULT IN MISMATCHED STOP/

TURN LIGHTS AND IMPROPER SIGNALING.

WARNING

SS
TT

Passenger Side

Drivers Side

PAGE 11 OF 14

AERFOIL LID PARTS & ASSEMBLY OVERVIEW

REQUIRED TOOLS:

HAMMER
3/8” WRENCH

7/16” WRENCHES
PHILLIPS SCREWDRIVER,

5/32” ALLEN WRENCH
RUBBER MALLET

KKK

LLL

BBB

JJJ

EEE

FFF

GGG

DDD

III

CCC

HHH

AAA

Unfold AerFoil Cover [UU] and place face-up.
Install Handle [AAA] using two (2) each 10-24 x
1.25 Phillips Screws, 10-24 Nylock Nuts, 3/16 X
1 Fender Washers [JJJ, KKK, LLL]. [Figure 7]

STEP 11

TOOL: 5/32” HEX WRENCH

AAA

JJJ

KKK

LLL

[Figure 7]

PAGE 12 OF 14

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.

NOTE: This step will be easiest if someone
assists you.
Form AerFoil Cover [UU] around Bulk Heads
[UU] inserting edges of Bulk Heads into
groove of cover as you go. Attach at remaining
two corners with pre-installed Pin Nuts [DDD]
and Joint Connector Bolts [BBB] using the
same method used in STEP 12.

STEP 13

STEP 12

TOOL: 5/32” HEX WRENCH

BBB

DDD

STEP 14

TOOLS: 3/8” WRENCH, PHILLIPS SCREWDRIVER, DRILL, 1/4” BIT.

Place the AerFoil Lid on top of cage. You should be able to
engage the Adjustable Pull Latches pre-installed to End Panel

[KK]

once the Lid is positioned properly.

NOTE: If the “catch” of the Pull Latch does not meet the Latch
Keepers pre-installed on Bulk Head

[WW]

the “catch” can be

raised by spinning the “catch” counter clockwise or vice versa to
be lowered.

Drivers Side

Passenger Side

Place the AerFoil face down so the
inner groves are exposed. Unfold Bulk
Heads

[VV] and [WW]

and remove

the pre-installed Joint Connector Bolt

[BBB] from the ends of the Bulk
Heads. I

nsert the Bulk Heads into the

groove near the edge of the AerFoil
Cover

[UU] so the Bulk Heads cut

line faces the interior of the carrier

[Figure 6]. One Bulk Head

[WW]

includes

pre-installed silver Latch

Keepers, be sure this Bulk Head is
placed on the Passenger side of the
vehicle

Re-Insert Joint Connector Bolts

[BBB]

through the pre-installed

Pin Nuts

[DDD]

and tighten.

[Figure 6]

DDD

BBB

Cut Line

Latch Keeper

Adjustable Pull Latch

AAA

PAGE 13 OF 14

NOTE: This step will be easiest if
someone assists you.

IMPORTANT: Remove and reattach
each bolt ONE AT A TIME before
moving to the next bolt.
Join two AerFoil Bands [EEE] together
with one Band Spring [FFF] at the
ends with the smallest holes. [Figure
10] Repeat for the remaining two
AerFoil Bands and Spring. Attach the Band/Spring
assembly to the AerFoil Cover by bending the
assembly around the top edge of the Aerfoil with
the padded side of the straps placed against the
Cover as shown. Start at one corner by removing
one Joint Connector Bolt [BBB] and then re-
threading the Bolt through the larger hole at the
end of the AerFoil Band [EEE] and then into the
carrier cover [Figure 11]. Repeat this step for the other side of
the carrier with the remaining Band/Spring assembly.

STEP 15

TOOLS: DRILL; 1/4” & 13/16” BITS, 3/8” & 7/16” WRENCHES, HAMMER, CENTER PUNCH

NOTE: This step will be easiest if
someone assists you.
Attach the top of the Hinges located on
End Panel

[JJ]

to the Bulk Head

[VV]

on the

AerFoil Lid using 1/4-20 X 1.25

Bolts

[CCC]

, .3” X 1” Washers

[GGG]

and 1/4-20 Nylock Nuts

[ZZ]

[Figure 8].

CCC

GGG

[Figure 8]

STEP 16

7/16” WRENCHES

Attach the loose ends of each Balance
Cable

[YY]

to the AerFoil Cover

[UU]

with

1/4-20 X 1.5 Bolts

[III]

, 1/4-20 X 1 Fender

Washers

[HHH], .75” Washers [XX], and

1/4-20 Nylock Nuts [ZZ]

using the third

hole in from the corner of the lid as shown.
[Figure 9] (NOTE: Smaller .75” Washers

[XX] should be installed on the interior.)

STEP 17

TOOL: 5/32” HEX WRENCH

III

HHH

BBB

EEE

FFF

BBB

[Figure 9]

[Figure 11]

[Figure 10]

REMOVE &

REATTACH

PAGE 14 OF 14

ONE YEAR LIMITED WARRANTY

We warrant this Let’s Go Aero brand product during the time the original retail purchaser owns

it. This warranty terminates if a purchaser transfers the product to any other person.

Let’s Go Aero warrants this product to be free from defect in material and workmanship for

one year (retain your sales receipt for your records). Any product or part thereof found to be

defective within that period will be replaced without charge provided that: (1) the product was

not misused; (2) no alterations or modifications were made; (3) its failure was not a result of

normal wear expected in the use of the product; (4) the product or part is delivered, freight

prepaid, to Let’s Go Aero.

Manufacturers only obligation shall be to replace such products or parts proved to be defective.

A Return Merchandise Authorization is required prior to return. Please contact Let’s Go Aero

toll-free, at 877-464-2376 or 719-630-3800, or via email to support@letsgoaero.com to get an

RMA number.

No warranty is given for LGA products purchased outside of the United States and Canada.

To register your product, visit the Let’s Go Aero website at www.LetsGoAero.com

Technical Support

For assistance with this product, please contact us:

Let’s Go Aero, Inc.

4474 Barnes Road

USA

Phone: 877-464-2376 or 719-630-3800

Email: Support@LetsGoAero.com

To learn more about our products and stay informed about useful options for transporting all kinds of

gear with your carrier, be sure to visit our website: www.LetsGoAero.com

Patent and trademark protected.

Patent Numbers 6,609,725; 6,945,550; 8,079,613; D717718; 8,858,141; Patents Pending

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