Flat Pack Rack Installation Instructions
Note: We highly recommend checking the torque of each piece of hardware regularly. Failure to do so can result in the stays slipping and the rack coming dislodged. We also recommend the use of a strap or cord that goes around the headtube and uprights to secure the rack from tilting forwards. If mounted and maintained properly, the Flat Pack Rack is a very secure rack, but we advise these additional safety measures.
- 4mm hex
- 5mm hex
- 10mm wrench
- Felt tipped marker
- Fresh hacksaw blade
Decide which backstop system you intend to use. For this build, we’ll be using the Integrated Decaleur option for a Randonneur Handlebar Bag.
Mount the uprights to the platform using two M6 screws.
Install the Foot onto the fork crown. Washer goes on the backside, under the nut.
Install the Foot through one daruma assembly and tighten lightly. The Foot should go right through the middle of the rack. The daruma assembly will be offset.
Check the levelness of the rack and adjust accordingly.
Install daruma assemblies mirroring each other on the front slot for the stays. These will ultimately face in or out depending on your bike and clearances.
Slide the stay through the daruma and position the stay to the braze-on that it will attach to. You may need to trim a bit off the end of the stay. Measure the difference from the drilled end to the braze-on.
And mark the cut point on the end of the stay using a marker.
Trim the excess using a fresh hacksaw blade. Remember, you can trim more off, but you can't put it back on.
File the end to clean it up.
Remount the stay to confirm the trimmed length and repeat for the other side.
Continue adjusting until the rack is level from the side as well as from the front. Tighten everything down.
Install the handlebar bag/basket/accessory per the manufacturer’s instructions.
If you want the added capacity of four stays, follow the above instructions and add two additional darumas to the rearmost slot. The stays can be mounted on the same fork mounting point, or another braze-on depending on your fork's design.
You may need to cant one of the daruma screws on the rearmost stays to be able to properly tighten the assembly.