Installation

Assembly instructions for Triple M angled Headboard Aluminium Tray.

Required Tools: Power Drill, Shifting Spanner, Pop Rivet Gun & 5/32" (4mm) drill bit
All components are supplied with the kit and labelled for easy identification.
Kit Components:
(a)  Instruction leaflet (b)   M10x20mm bolts (c)   Side rail inserts
(d)  M10x25mm bolts (e)   M10 nylock nuts (f)   Pop rivets
(g)  Care Instructions (h)   Bungy buttons (i)   Template for bungy button placement
(j)  Side rails (2) (k)  Tonneau bows (l)   Rear Frame (3 pce)
(m) Canopy (n)   Frame sockets optional extra where not already fitted (o)  Front mounting plates (LH &  RH)
FRAME INSTALLATION
Step 1. Mounting Plates - Remove the two bolts in top left hand corner of headboard. 
           Using two M10x25m bolts and nuts, fit left hand mounting plate. Repeat
           process for right hand side.  These do not need to be removed again when dismantling.
                                      
Step 2. Ladder Rack Sockets - (If already fitted go to step 3)
             *Correct positioning is critical*
            Some models will already have the rear side hole. Use this for positioning the
            Socket. Where this is not the case, place left hand socket with the rear edge of
            the base plate in line with the rear edge of the aluminium plank corner. Ensure
            rack tightening bolt is facing to the rear before drilling.
            * Check* rear edge of socket base plate should be 12mm in from the outside
            edge of the tray.
            * Check* close tailgate and ensure that there is minimal clearance between
            tailgate and socket.
                                            
             First drill outer holes in tray lip, secure using spacers, bolts and nuts supplied
            with socket set.
            Drill two holes into floor of tray and fit support plates under tray. Repeat for
            right hand side, facing tightening bolt outwards to rear of tray.
  
                                                                                                                       
Step 3. Rear Frame - Assemble the rear frame by attaching the top rail to the left and
            right hand uprights using four M10x20mm bolts, spring washers and flat washers.
           The side rail mounting brackets should be facing towards the front. Fit the rear
            frame into both sockets. Rear corner of frame should be directly above the rear
           corner of tray, lightly tighten locking bolts to secure frame.
 
Step 4. Side Rails  (Some shorter side rails are supplied in one piece).
           Assemble side rails by joining using inserts and bolts M10x20mm
            provided. Drop in the two side rails with black bow brackets facing inwards. 
            Secure with nylock nuts.
           
                                        
Step 5. Bows - Drop two curved bows into brackets on side rails
                                                          
 
             Your frame is now complete.
 
CANOPY INSTALLATION
 
Step 1. Place canopy on top of frame starting at the front and roll out towards rear.
            Slide front panel between headboard and cabin window ensuring the two ropes
            attached drop under the body.
 
Step 2. Pull side and rear flaps over frame. Ensure inside roll up straps are over the
            top of the frame.
 
Step 3. Make sure all corners are positioned evenly over the frame and are a snug fit.
             Close all zips.
 
Step 4. Using button gauge, mark positions for holes directly under (perpendicular)
             each bungy loop.
            
                                  
            *Check point* The holes should be 160mm or 170mm from the top of the drop side. Depending
                                    on tension required. 
Step 5. Drill all holes using 5/32" (4mm) drill bit. Fit all buttons using pop rivets .
                                                                                                    
                                         
Step 6. Pass front tie down ropes inside and behind vertical headboard member and under
            chassis rail. Ensure PVC sleeve is in position to protect rope from sharp edges of 
            chassis rail. Feed end of rope around side rope rail and back through the
            loop spliced into the rope. Pull back to tension and tie off using clove hitch
            around rope rail.
                            
Step 7. Pull bungy loops on to buttons.
 
Step 8. Hose canopy to set the seams and allow to dry while still on the vehicle all zipped closed and tied down.
            Do not remove from vehicle for storage until completely dry.