Required assembly tools are: Phillips head screwdriver attachment, 9/64 inch drill bit, electric drill, pop rivet tool, scratch all, standard flat screwdriver, 3/8 inch combination wrench, utility knife, safety goggles, and protective gloves.
Recommended assembly tools are: pneumatic drill, c-clamp vice grip, quarter inch drive ratchet with 3/8 deep socket, and pneumatic pop riveter.
How to Use a Pop Rivet Tool:
Insert the shank of the pop rivet into the mandrel of the pop rivet tool. Insert the rivet head through the two pieces of steel. Compress the tool’s level handles together until the rivets shank separates from the head of the rivet.
The outside floor has seven half circle tabs cut into the floor with 1 1/4 inch hole for the power cord of the optional floor heater.
Step 1: Left Wall Panel
Align the center hole of the left wall panel with the center hole of the left floor tab and attach with a rivet. To assure a perfect fit, ream each hole with a 9/64 inch bit before attaching with rivets.
Right Wall Panel: Step #2
Repeat the attachment procedures from step one in attaching the right wall panel.
Step 3:
Insert the edge of the back wall panel fully into the groove of the right and left wall panel. Attach by aligning the holes in the wall with those in the floor tab.
Step 4:
Insert the edge of the left wall panel into the groove of the front wall panel. Align the pre-punched holes of the front wall panel with the holes of the front tab.
Step 5:
Align the pre-punched holes of the door plate, front wall panel, right wall panel, and liner stops. The door plate overlaps the front panel. The rivets connect the door plate, front wall panel, right wall panel, and liner stops shown.
Step 6:
Drill a 9/64 inch hole through each panel groove and each wall panel approximately six inches from the top edge of the wall.
Step 7:
Fasten with rivets.
Step 8: Insert the front insulation panel measuring 13x24 inches. Insert the right insulation piece measuring 24x25 inches.
Step 9:
Slide the ends of the inside plastic wall into the liner stops. Insert the rear insulation panel measuring 24x28 inches, with the left at 24x25 inches.
The corner insulation pieces are bendable. After installing the insulation panels, pre bend the corner pieces to conform into the corners. Insert the 8 ½ inch foil faced corner pieces into the right and left rear corners, with the 6 ½ piece in the front left corner.
Step 10:
Locate the front tab and bend up to a right angle. Invert the steel inside floor and place the precut insulation within its rim. Insert the steel floor with the steel side up. Push the floor down until it rests evenly with the front edge of the floor behind the front tab.
Insert the rubber grommet into the 1 1/4 inch hole. Press down on the insulation to imprint the grommet shape into the insulation. Cut a hole in the insulation large enough for the heater cord to pass through the floor.
Use lubricant such as silicon or light oil on the heater cord plug to allow the cord to pass through the grommet. Place the heating mat on the top of the insulation. Install the two spacer pieces of insulation. Replace the steel interior floor on top of the heating mat.
Step 11:
Install the 31 ¼ inch right wall support with its notch in near the door plate corner. The corner supports are installed under the wall supports. Install the 28 ¾ inch back and left wall supports.
Install the front wall support with the right half of its length placed between the front wall and door plate. Align the holes in the supports with the wall panels and attach with rivets. The last hole on each end of the support must be drilled and riveted. DO NOT drill holes in the liner yet.
Step 12:
Make sure that the inside wall liner is tight against the insulation. Drill and rivet the remaining wall supports to the liner and inside metal corners.
Step 13:
Drill and attach the liner stops to the inside wall liner.
Step 14:
Lift the six metal floor tabs to form a right angle with the floor. Attach the chew guards to the floor into the floor tabs with 14 pan head screws. Insert one deck screw into the middle support.
Step 15:
Attach the door cowl assembly to the front side of the door plate with #10x32x3/8 inch machine bolts, lock washers, and nuts. Do not fully tighten the bolts yet. Insure that the door swings freely without striking the door plate before fully tightening. If the door strikes on the door plate on the right, raise the left side of the assembly. If it strikes on the left, raise the right side of the assembly.
Step 16:
Peel of the paper from the weather stripping as you push the adhesive side of the weather stripping to the top of the wall supports.
Step 17:
Place the lid on top of the wall. Allow the latch to hang from the latch strike that is attached to the left and the right sides of the lid. Mark the location of the bottom hole of the latch on the wall with a scratch all. Attach the latch to the wall by inserting one small self tapping screw in the bottom hole at the spot mark. Insert one small self tapping screw into the top hole. Insert the latch catch pin.
Door Use and Maintenance:
With the door in the open position, insert the locking pin through the hole in one side of the rain shield and through the other. Insert the locking pin through the rain shield and the two notches in the door. When not in use, insert the locking pin in the top holes of the rain shield.
GUN DOG SUPPLY - "Serving Hunting & Field Dog Owners Nationally Since 1972."
Order online via Secure Server or call 1-800-624-6378 to order! GDS Warehouse, 312 Industrial Park Road, Starkville, Mississippi, 39759 USA.
