NOTE: The following Instructions are for use with a special "Assembly Platform" This platform is availiable when assembling large numbers of Shells for a fleet application.
The Tailgater™ SecureShell™ arrives partially assembled in five major components. You will receive a Roof Assembly, two Side Panels, a Front Panel, and a Rear Panel with door. Also included with the five panels is a Lower Support Channel and all required hardware and gasket materials required for the assembly.
The following instructions require the use of a special Assembly Platform available separately from Tailgater™. Because the panels are large and bulky, two people are recommended to perform the Assembly. Do not attempt to lift pieces alone. Please observe all proper lifting techniques and safety procedures throughout the assembly process. Please preview the following instructions before you begin. Contact Tailgater's Engineering Department with any questions.
Tools Required: Scissors Pneumatic Pop Rivet Gun Hand Drill 13/64" Drill Bit Sealant Gun 3/8" Drive Ratchet with Long Ratchet Extension, Ratchet Swivel Connector 7/16" and ˝" Deep Sockets 7/16" and ˝" Wrench Small Brush Air Blast Attachment with Air Compressor Phillips Screwdriver 3/8" Socket Driver Adjustable Clamps
Notice: Always follow proper safety procedures for handling power tools, eye protection, hearing and proper lifting techniques. If you are not sure about these procedures contact your supervisor before proceeding with assembly.
Assembly Overview: A view of the SecureShell™ assembled on the Platform is shown. First, the Top and Side panels will be assembled. The truck bed will be prepared with Pocket Loks™ and the bed rail will be lined with Foam Tape. Next, four people will carefully move the partially assembled shell onto the truck. Before completing assembly any interior accessories should be installed at this point. Finally, the Rear Panel will be installed, and the assembly will be complete.
INSTRUCTIONS:
Step 1 Place the Roof Assembly on top of the Platform. Lock into four blocks. Locate the CAB end of the Roof Assembly.
Step 2 Place the Side Panels on Platform. Allow Panels to rest against the Platform's inner frame.
Step 3 Place 5/16 x 2" Hex Bolts, at all four corners, approximately 1 2/16" in from the end.
Step 4 Mount String Gasket into Extrusion Grooves along both sides.
Step 5 Now, lift the Roof Assembly and align the bolts to Side Panel Bolt Track holes at each end.
Step 6 Tighten corner bolts with Flat Washers and Nyloc Hex Nuts.
Step 7 Place Die-Cut Gaskets at all four corners. Peel n' stick to surface.
Step 8 Peel n' stick the Thin Foam Tape along the top and down the sides of each end of the assembly. Leave 1" of backing paper at each end as shown.
Step 9 Cut the Foam Tape to fit snugly against the Corner Gasket. Next, peel n' stick the ends of the Foam Tape.
Step 10 At the CAB end of the assembly, place a 5/16 Spring Nut in the lower leg, approximately ˝" from the bottom, on each side.
Step 11 Mount the Bolt Track to Channel Ends with hardware shown. Be sure the angled cuts on the Channel match the angled cuts on the Bolt Tracks.
Step 12 Align the Support Channel to the Spring Nuts on each side. Place 2" Hex Bolt and Washer and tighten into Spring Nut.
Step 13 Place Thin Foam Tape across Support Channel. Set and clamp the Front Panel in mounting position.
Step 14 Using a hand drill with 13/64" drill bit, drill through all panel pilot holes into assembly. When completed, set the Front Panel aside.
Step 15 Next, brush off all drill chips with a small brush and remove small particles with a compressed air blast. (Wear Safety
Glasses)
Step 16 Apply a Latex/Silicone Sealant around the edge of the shell. Good coverage in all corners is important.
Step 17 Replace Front Panel and Pop Rivet the panel to the shell assembly through the previously drilled holes.
Step 18 Scrape off any heavy buildup of sealant then wipe smooth with a wet cloth. Finish surface with a dry cloth.
Step 19 This completes the assembly of the first three sides of the shell. Prepare the truck bed with Pocket Loks™ and foam tape as follows.
Step 20 Assemble and mount Pocket Loks™ according to provided instructions.
Step 21 Apply 3/8" x 2" Grey Foam Tape to the side rails of the truck bed. Apply 1/2" x 1" Black Foam Tape to the cab end rail of the truck bed.
Step 22 Place Nylon Spacers over Mounting Bolts at each pocket location. Cut the Foam Tape around the Spacer and remove
exceess Tape. Place Spacer over bolt, flush with the Foam Tape.
Step 23 With help from three other people, lift the Assembled Shell off the Platform onto the prepared truck. Align Mounting Holes to Pocket Studs and rest Shell Assembly on truck bed.
Step 24 Fasten the Shell Assembly to the truck bed using a Fender Washer, Flat Washer, and Nyloc Hex Nut.
Step 25 Prepare Rear Panel for installation. Apply Foam Tape to Rear Lower Rail and mount Bulb Gasket to lower sides of Rear Panel.
Step 26 Place and clamp Rear Panel into position. Drill 13/16" at pilot holes, remove panel, apply sealant, replace panel, pop rivet panel to assembly and wipe excess sealant.
Step 27 Install Self-taping Screws along bottom edge of Rear Panel through pre-drilled holes.
Step 28 Attach the Rear door Holder, as shown, with supplied hardware and instructions.
Step 29 Mount and wire the Third Brake Light with supplied hardware and instructions.
Step 30 The two Side Doors are held open by two Gas Struts, one at each end of the door.
Step 31 The Rear Door is held open with a plug and socket device that will hold until you pull to free it.
Step 32 Thank you for taking the time to assemble the Tailgater™ SecureShell™. If you have any questions, feel free to contact us.
