Poison Spyder LJ HEAVY DUTY HEADER BAR - Manual

INSTALLATION INSTRUC
TIO
NS
©2014 POISON SPYDER CUSTOMS, INC. • 951-849-5911 • WWW.POISONSPYDER.COM
TJ/LJ HEAVY DUTY HEADER BAR INSTALLATION
The Poison Spyder Customs Heavy Duty
Header Bar Kit is easy to install with the right
tools and good mechanical abilities. If you are
not confident in your mechanical skills, please
seek the help of a professional to perform the
installation. Please read through these entire
instructions before proceeding with installation.
PARTS LIST
(1) Right Heavy Duty Header Bar (2-piece)
(1) Left Heavy Duty Header Bar (2-piece)
(2) 7/16-20 X 2-1/2 Gr8 Hex Head Cap Screw
(2) 7/16-20 Grade ‘C’ All-Metal Lock Nut
(4) 7/16 Flat Washer
TOOLS NEEDED
• 11/16” wrench
• 5/8” socket, ratchet and torque wrench
• T-50 “Tamper-Proof” Torx driver bit
(available from Poison Spyder Customs)
BEFORE YOU BEGIN
The Poison Spyder Customs Heavy Duty
Header Bar Kit comes as unpainted, bare steel.
You will want to either powder coat or paint the
components prior to install. If painting yourself,
careful preparation will make a big difference in
the quality and longevity of your paint job, even
when using “rattle can” aerosol paints. Begin
by thoroughly cleaning the components with
solvent or de-greaser, then make sure all residue
is removed. Even if you use cheap paint, try to
use a good quality primer. “Etching” primers are
best to use on bare, unpainted metal. Allow it to
properly dry before painting, and between paint
coats.
If powder-coating, mask off the tube area of the
short pieces. These are a slip-fit into the long
tube sections, and the thickness of the powder
coat may hinder assembly of the pieces.
INSTALLATION PROCEDURE
1. Park vehicle on a level surface and set the
emergency brake. You will want to wear eye
protection beyond this point.
2. Remove the top, door surrounds and any
other obstructions to the header bars.
2. Remove the factory header bars. You may
need a T-50 “Tamper-Proof” Torx bit for the
rearward bolts that attach the header bars to
the factory roll bar. Keep the removed Torx
bolts as they will be re-used.
3. Install the Heavy Duty Header Bars using
the factory Torx bolts. Note that the Heavy
Duty Header Bars are specific for right and
left sides. Orient them with the short piece
attached to the roll bar, and the long piece
attached to the windshield frame. Make
sure the through-holes in the short piece are
aligned with the slots in the long piece, then
tighten the Torx bolts. Note that there are
two sets of bolt holes on the plate, to fit the
two different model year ranges. The unused
bolt holes will be left empty.
4. Insert a 7/16-20 X 2-1/2 Gr8 hex head cap
screw with 7/16 flat washer through the slot
and hole where the two tubes overlap. Install
a 7/16 flat washer and 7/16-20 Grade ‘C’ all-
metal lock nut onto the end of the cap screw.
Tighten the nut then torque to 40 ft.-lbs.
Repeat for other side.
5. Re-install the factory door surrounds,
top, and any other components that were
removed prior to installation. The Poison
Spyder Heavy Duty Header Bars come
with properly located mounting holes for re-
installation of the door surrounds.