American Expedition Vehicles Cab Closeout - Manual (Page 4)

Page 4 of 6
doors close easily and sit flush in the opening. Sight down the side of the vehicle and be
sure that the doors aren’t sticking out at the top or the bottom indicating that the closeout
is racked to one side, or spread out at the top (two very common issues at this point).
Compare the cross car measurement to your initial measurement before the tub was cut.
Use a straight edge to be sure the doors are level with the body side, check in several
locations. Align the Closeout in the for/aft dimension. Clamp a straight edge across the
back of the Closeout assembly and check for an overall cab dimension of 61” from the
front of the cab (where the fender bolts on) to the back of the cab. Check that the door
sill is parallel at the seam and that there is an even parallel gap all along the bottom of
the door. Clamp the bodyside to the downward facing flange on the floorpan under the
doors to set the angle of the closeout.
6. Attach the J-Rails. Cut and reuse the J-rails removed earlier. Drill the hardtop mounting
holes as shown and plug weld the J-rail to the Closeout using the holes drilled earlier to
remove the factory spot welds. Weld the seams carefully so as not to get weld in the
groove underneath where a soft top would slide in. Finish out the welds with the sander
and ScotchBright pad.
7. At this point you may choose to test fit the Brute Hardtop. Install the header latches and
hardware from the factory hardtop. DO NOT USE SOFT TOP OR AFTERMARKET
LATCHES. Test fit and check gaps between the doors and the hard top.
8. Lock down the closeout. Once you are satisfied with the door gaps and all critical
measurements:
• Tack weld the three holes in the Closeout bodyside to the Doubler plate.
• Tack weld the floorpan to the outside Waterfall sections of the closeout.
• Tack weld the Longitudinal Strainer of the tub and Closeout.
• Once everything is tacked in place, MIG weld the areas shown.
• Weld the Bodyside to the Floorpan.
• Weld the Door Opening and Latch area to the Porkchop.
9. Weld and blend the door sill return flange. Use the hammer to lightly bend the return
flange on the Closeout to the return flange on the tub under the door, once its bent in, run
a small MIG weld on that area.
10. Finish the seams out. Using the 80 Grit sanding disks and ScotchBright pads, finish your
seam welds out as best as possible.
11. DO NOT WELD ON THE REAR CAB BODY MOUNTS AT THIS TIME.