WEATHER GUARD 644-X-01 through 685-X-01 - Manual (Page 2)

2
INSTALLATION INSTRUCTIONS
Note:
• If your pickup is fitted with a plastic drop-in bed liner, it may
need to be drilled, trimmed, or cut for proper installation of
truck box.
• Truck box cover may not properly latch until box is fully bolted
to truck bed.
• Periodically check tightness of mounting bolts to insure
proper attachment.
• Use touch-up paint on any drill holes to prevent oxidation.
• Install boxes with vehicle parked on level ground.
Step 1: LOCATE BOX IN TRUCK BED
• Place box in truck bed and center. Check for interference with box cover
open.
• Select two ribs in truck bed on which to mount box (preferably outside of
frame rails).
• Measure from middle of selected rib to truck box end (dimension "X" in
figure 1).
• Transfer dimension "X" to inside of both sides of truck box.
• Mark a line 3"-4" from front and back on inside of truck box.
Note: Fasten truck box directly to bed floor, not bed liners or mats.
Note: A drop of oil or grease should be applied to both faces of
grommets before tightening the fasteners to prevent grommets from
binding on washers.
Figure 1
Step 2: DRILL MOUNTING HOLES
• Drill 3/8" holes through box and truck bed at marked locations.
Note: For a one person installation, if desired, the box may be installed using blind fasteners, eliminating the use of nuts
and washers on the underside of the bed. In this case, re-drill the 3/8" holes in the bed with a 1/2" drill bit. See Blind Fastener Installation on next page.
Note: For a regular installation, use a blind fastener in areas where standard fasteners can't be used, such as heat shields and support channels. See
Blind Fastener Installation on next page.
• Install (4) rubber grommets into holes in the box.
CAUTION
WARNING
Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, brake lines, electric wires, etc., check under vehicle for locations.
Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct safe
drilling.
CAUTION
To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear protective eye wear.
WARNING
All floor mounting bolts near the gas tank area should be installed from the underside of the vehicle, to guard against the gas tank
being punctured in the event of a collision. This would mean not using Blind Fastener in this area. Holes drilled in this area should be
3/8".
Step 3: ATTACHING ALL-PURPOSE CHEST TO TRUCK BED
Select 1 of 4 mounting styles that fits your application:
Style 1: No bedliner, using through bolts
Style 2: Bedliner, using through bolts
Style 3: No bedliner, using blind fasteners Style 4: Bedliner, using blind fasteners
Frame Rails
Drill 3/8"D holes
"X"
3"- 4"
3"- 4"
All Purpose,Fig.1.eps
Mtg.Style1.eps
5/16" x 1-1/4" HH Bolt
5/16" Flat Washer Box
5/16" Flat Washer
Rubber Grommet
5/16-18
Nylon Lock Nut
Floor Rib
Mtg.Style2.eps
5/16" x 1-1/4" HH Bolt
5/16" Flat Washer
Box
5/16" Flat Washer
Rubber Grommet
Bedliner
5/16-18
Nylon Lock Nut
Floor Rib
Floor Spacer
Mtg.Style3.eps
5/16" x 1-1/4" HH Bolt
5/16" Flat Washer
Box
Installed
Blind Fastener
Rubber Grommet
5/16" Lock Washer
Floor Rib
Mtg.Style4.eps
Bedliner Floor Spacer
5/16" x 1-1/4" HH Bolt
5/16" Flat Washer
Box
Installed
Blind Fastener
Rubber Grommet
5/16" Lock Washer
Floor Rib