WEATHER GUARD 163-X-01 (01) PDF Document

ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.

DANGER

Danger of explosion. Do not use this product for storing or transporting flammables, explosives, hazardous materials, or hazardous waste, such as containers of gasoline, solvents, gun powder, dynamite, propane tanks, acetylene tanks and cutting torches. This product is only intended and safe for use in storing and transporting small tools, equipment and other similar materials. Any modifications made to, or unintended use of this product, could create a hazardous condition that can cause death, serious personal injury or property damage.

WARNING

Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, electric wires, etc., check under vehicle for locations. 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″.

CAUTION

Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct safe drilling. To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear protective eyewear.

NOTICE

Use specific aluminum upfit components when installing WEATHER GUARD® products to aluminum truck beds. Follow additional instructions if mounting to an aluminum truck bed. There may be left over components depending on upfit.

Any modification or unintended use of this product shall immediately void all manufacturers warranties. Manufacturer disclaims all liability for injuries to persons or property resulting from any modification to, or unintended use of this product.

The following tools are required for installation:

• Electric Drill

• Drill Bits – 3/16″, 3/8″, 1/2″

• Open or Box End Wrenches – (2) 1/2″, 9/16″

• Hammer

• Oil/Grease

• Center Punch

• Carpenter’s Square

• Pencil/Marker

Follow these steps for blind fastener installation:

1. Place a drop of oil on the black oxide bolt for lubrication before assembling.

2. Place the Blind Fastener in the hole and use a 1/2″ or 7/16″ wrench to tighten the black oxide bolt until the fastener is fully seated. It will start out hard and get easier as the fastener “bulbs” out.

3. Make sure the Blind Fastener and Installation Tool do not turn during installation.

When installing a blind fastener on an aluminum truck bed:

1. Coat drilled holes with Zinc Rich Primer.

2. Insert the Blind Fastener through one 1/2″ x 1″ plastic washer.

3. Insert the Blind Fastener into the drilled hole.

4. Place a second 1/2″ x 1″ plastic washer through the bottom of the Blind Fastener.

5. Continue following the standard blind fastener installation instructions to install the Blind Fasteners.

Additionally, when mounting with a clamp or “J” bolt, use vinyl tape as a barrier between the mounting clamp and the truck bed.

Please note the following before and during installation:

• If your truck bed is constructed of aluminum, use zinc rich primer to coat drilled holes.

• 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 the truck box.

• The truck box cover may not properly latch until the box is fully bolted to the truck bed.

• Periodically check the tightness of mounting bolts to ensure proper attachment.

• Use touch-up paint on any drilled holes to prevent oxidation.

• Install boxes with the vehicle parked on level ground.

Note: Fasten the box and leg mounting feet directly to the bed floor, not to bed liners or mats.

1. Place the box into position with the cover open. Support the box as required during installation.

2. Verify the tailgate closes with the mounting angle in position.

3. The bottom of the box should be flat on the floor.

4. The side of the box (not the cover) should be approximately 1″ from the bed rail.

Note: This step may be omitted if you are able to use the alternate method in Step 3A. Make sure there is enough hole depth before installing the blind fastener.

1. Place the mounting angle against the end of the box with its foot touching the stake pocket (or inner wall of the truck bed).

2. Mark one hole on the box and one hole on the truck. Center punch the holes to be drilled.

3. Drill the truck box and stake pocket (or inner wall) with a 3/16″ drill bit.

4. Re-drill the hole in the truck box with a 3/8″ drill bit.

5. Re-drill the hole in the stake pocket (or inner wall) with a 1/2″ drill bit.

6. Install the Blind Fastener in the stake pocket (or inner wall).

7. Install the mounting angle.

For Aluminum Truck Beds: Follow the additional instructions for mounting to an aluminum truck bed as explained in the Blind Fastener Installation section.

Note: Install bolts from the underside when fastening the mounting angle to the wheel well. This step may be omitted if you are able to use the alternate method (Step 3B).

1. Place the mounting angle under the box and against the wheel well.

2. Mark one hole on the bottom of the box and both holes on the wheel well. Center punch the holes to be drilled.

3. Drill the truck box and wheel well with a 3/16″ drill bit.

4. Install the mounting bracket.

For Aluminum Truck Beds: Follow the additional instructions for mounting to an aluminum truck bed as explained in the Blind Fastener Installation section.

Yes, Step 3B is an alternate method to be used if the truck configuration allows the box to rest directly on the wheel well.

Note: Install bolts from the underside when fastening the Mounting Angle to the wheel well.

1. Mark, center punch, and drill a 3/16″ hole in the bottom of the box and the top of the wheel well as shown in the installation manual figure.

2. Re-drill the holes with a 3/8″ drill bit.

3. Install the bolt as shown in the manual’s figure.

Note: If the holes in the Floor Mounting Angle are not positioned above a rib, use the Floor Mounting Spacers provided.

1. Place the floor mounting angle on the floor, centered behind the box.

2. Mark, center punch, and drill all four holes with a 3/16″ drill bit.

3. Re-drill the holes in the box with a 3/8″ drill bit.

4. Re-drill the holes in the truck bed with a 1/2″ drill bit.

5. Install the Blind Fasteners in the truck bed.

6. Install the floor mounting angle as shown in the installation manual figure.

The WEATHER GUARD® Extreme Protection™ Lock is designed for maximum security and ease of use.

To Lock:

Turn the key counterclockwise to the locked position as indicated on the lock bezel. When the button is now pressed, it will stay in the retracted or tamper-resistant position until unlocked.

To Unlock:

Turn the key clockwise to the unlocked position as indicated on the lock bezel. The button will pop out and is now ready to release the latches when pressed.

The WEATHER GUARD® Latch System is designed to open with a single touch of the button and close securely. It utilizes automotive-grade latches with high-strength latch strikers.

Maintenance: For reliable service, lubricate the latch pivot points bi-annually with white grease.

Troubleshooting: If the latch strikers are accidentally knocked out of alignment, simply use a mallet to re-align them.

The following table lists the available service parts. Note: ‘X’ in the part number represents the color code for your model: 0 = Clear | 3 = White | 5 = Black. ‘XX’ in the part number represents the key code.