CJ-7 FULL CAGE KIT INSTALL

Transcription

INSTALLATION INSTRUCTIONS
CJ-7 FULL CAGE KIT INSTALL
C-Pillar Mount Plates, if you have a factory bar.
At the least, you will need an additional (8) 3/8”
(dia.) bolts, nuts and washers, for the A-Pillar
Mount Plates. The length will vary, depending
on your installation. Use only quality, Grade 8
hardware and lock nuts.
TOOLS NEEDED
• Mechanic’s tool set
• Ratchet straps
• Dead-blow hammer
• Measuring tape & carpenter’s square
• Brake cleaner & shop rags
• Welder and proper welding equipment
• Protective welding blankets
Thank you for purchasing a Poison Spyder Full
Cage Kit for your Jeep CJ-7. Poison Spyder’s
innovative Lazer-Fit technology provides for the
easiest, fastest installation of any aftermarket full
cage kit on the market. Installation does require
specialized skills and tools, such as welding. 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.
CHECK YOUR PACKAGES
Please check your packages immediately upon
arrival to ensure that everything listed is included,
and to check for damage during shipping. Use
the diagram and Parts List on the next page to
identify each part. Tubular components are laseretched with the identification numbers shown
(plate components are not marked) Note that
the parts as depicted in the drawing might not
exactly match the actual part in shape, length,
bends, etc. If anything is missing or damaged,
call Poison Spyder at (951) 849-5911 as soon as
possible.
NOTE: In addition to the parts supplied in the kit,
you will need to source your own hardware to
bolt the cage in. In some cases you may be able
to re-use the OE hardware, such as at the B- and
INSTALLATION NOTES
The Full Cage Kit will work with the factory Jeep
soft top. Duster rear deck covers, “windjammers”
and short style bikini tops will work. However,
“safari” style bikini tops will not fit. Children can
ride in the back seat but the Poison Spyder Full
Cage Kit was NOT designed to accommodate
adult passengers in the OE back seat.
Installation of the Full Cage Kit can take up to 8
hours. This kit requires welding, which should
be done by a certified welder. You will need a
friend or two to assist with the installation.
IMPORTANT: It is imperative that the top, doors,
seats, plus any other components that are going
to be reinstalled after the cage install be testfitted BEFORE final welding of the cage! Poison
Spyder Customs is not liable for fitment issues
due to negligent install.
INSTALL PROCEDURE
NOTE: In most cases, the laser-cut notches and
laser-etched assembly marks will eliminate all
guesswork. Regardless, carefully inspect each
part and its placement prior to tacking and finishwelding. Also, each step should be extrapolated
for both sides, where any procedure is to be
duplicated on both sides of the cage.
©2011 POISON SPYDER CUSTOMS, INC. • 951-849-5911 • WWW.POISONSPYDER.COM
Poison Spyder Customs • CJ-7 FULL CAGE KIT INSTALL
18
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1
8
8
4
15
15
11
11
2
2
12
16
16
3
3
10
14
14
17
1. Park vehicle on a level surface and set
the emergency brake. You will want to
wear eye protection beyond this point.
2. Remove any existing hard top, soft top
and associated bracketry, front seats, roll
bar or cage, and spreader bars if present. Save any bolts that mounted the OE roll
bar to the floor, as these may be reused during the install of the new Poison
Spyder cage. Place welding blankets or
some sort of protective covering over the
Jeep’s dash and interior to protect it from
weld splatter.
3. If your Jeep uses knobs with large
handles to bolt the windshield in place,
you will need to remove these and
replace them with a standard bolt in order
to install the cage as close to the dash/
windshield as possible.
PARTS LIST
(2) A-Pillar Mount Plate L&R
1
(2) B-Pillar Mount Plate L&R
2
(2) C-Pillar Mount Plate L&R
3
(1) A-Crossbar
4
(tube unmarked)
(2) Main Side Hoop L&R
(1) C-Hoop
8
10
(2) B-Pillar L&R
(1) B-Crossbar
11
12
(2) C-Pillar L&R
14
(2) Forward Stringer L&R
15
(2) Rearward Stringer L&R
(1) Seat Belt Bar
(1) Dash Bar
16
17
18
Page 2
4. Clean ALL bare metal pieces provided in the
kit, using a clean rag and brake cleaner. This
will ensure an easier, cleaner installation and
better welds later in the installation.
5.Position the A-Pillar Mount Plates 1 ,
B-Pillar Mount Plates 2 , and C-Pillar Mount
Plates 3 into their approximate locations. Use the OE hardware to bolt the B- and
C-Pillar Mount Plates into place, but leave
the bolts loose so that slight adjustment may
be made to the plates’ position. You will have
to drill holes for the A-Pillar Mount Plates, but
wait until later steps to do this.
6. With the help of a friend, place the Main Side
Hoop L&R 8 into the Jeep on either side. The bend of the hoop that closely follows
the line of the Jeep’s dash and windshield
will rough positioning easy. Have your friend
continue to hold each hoop roughly in place.
Page 3
these etched marks. It may be necessary to
slightly loosen the ratchet straps to allow the
tube ends to slide into place.
10.Place the Dash Bar 18 between the two Main
Side Hoops just above the dash of the Jeep,
and secure it into place with another ratchet
strap, and use the dead-blow hammer to
tap it into alignment with the laser-etched
placement marks. Note that if your Jeep is
not equipped with the factory dash pad, you
may be able to lower the Dash Bar to obstruct
less of the windshield. If you do this, make
sure to take proper measurements to ensure
placement and squareness of the Dash Bar. At this point the cage assembly, though held
together entirely with ratchet straps, should
stand on its own, so you may relieve your
friend of his holding duties.
7.Place the A-Crossbar 4 between the
two Main Side Hoops near the top of the
windshield frame. Use a ratchet strap to
snug the two Main Side Hoops toward each
other, with the A-Crossbar holding them
apart. Have your friend continue to hold up
this 3-piece assembly.
FIGURE 10
FIGURE 10
8. Place the B-Crossbar 12 between the two
Main Side Hoops near the rearward bends in
the Side Hoops. Apply another ratchet strap
to tighten this end of the assembly. Have
your friend continue to hold up the assembly.
11.Fine-tune the position of the cage within
the Jeep. Start by making sure it is close
to the dash with a quarter inch or so of
clearance. Then measure between the edge
of the Jeep’s tub and the Main Side Hoop,
ensuring that this distance is equal on either
side of the Jeep. Repeat this at the rear
section of the Main Side Hoops and at either
end of the A-Crossbar and B-Crossbar.
9. Inspect the surface of each Main Side
Hoop, on the interior side of the tube, looking
for the circular tube placement marks which
have been laser-etched into the tubing. Use
a soft dead-blow hammer to tap each end
of the two Crossbars into alignment with
Page 4
FIGURE 10
FIGURE 10
Use a square to ensure that the Crossbars
are exactly perpendicular to the Main Side
Hoops, and that the Main Side Hoops are
perpendicular to the Jeep’s floor. Use a dead
blow hammer to gently tap the components
into adjustment. Work your away around the
assembly a couple of times, as adjustments
you make at one end may affect the placement
at the other. During this procedure, ensure
that the ratchet straps stay tight and Main
Side Hoops remain firmly seated into the
laser-cut notches of the Crossbars.
13.Place the B-Pillar L&R
into position on
either side of the Jeep. Each B-Pillar is
positioned vertically, from the B-Pillar Mount
Plate to the Main Side Hoop. Use the laseretched placement marks along the underside
of the Main Side Hoop to position the B-Pillar,
and tack-weld it to the Main Side Hoop (do
not tack it to the Mount Plate yet).
11
FIGURE 10
FIGURE 10
12.Tack-weld the cage at each joint of the
assembly so far. These tack welds should be
big enough to temporarily hold the assembly
together, but small enough to still allow slight
adjustment of the tubes, or to allow easily
breaking and grinding of the tacks if further
large adjustments are needed. DO NOT tack
the tubular components to the Mount Plates
yet. Remove the ratchet straps.
14.
Place each Forward Stringer L&R 15
into position between the A-Crossbar and
B-Crossbar. Use the laser-etched marks
on each Crossbar to properly position the
Forward Stringers, and tack them into place.
FIGURE 10
15.This step is kind of tricky, you’ll definitely
need the help of at least one friend, but two
will make it much easier. Locate the C-Hoop
10 , C-Pillar L&R 14 , and Rearward Stringer
L&R 16 . All five of these components must
be fit together at the simultaneously and
tacked into place. Begin by placing the
U-shaped C-Hoop into place at the back of
the cage. The odd-shaped laser-cut notches
at either end will fit onto the downward curve
of each Main Side Hoop. There are no
positioning marks here, but the marks on the
rest of these parts will be enough to properly
position everything. Position each C-Pillar
into place, with the lower end on the Main
Side Hoop near the rearward Mount Plate,
and the upper end intersecting the bend of
the C-Hoop. Finally, position the Rearward
Stringers between the B-Hoop and the
insides of the bends in the C-hoop. With one
or more friends to help hold everything in
place, make sure all joints are firmly seated
in their notches and positioned in the laseretched marks. Then tack all of these pieces
into place. Again, do not tack to the Mount
Plates at this time.
Page 5
FIGURE 10
17.Make final adjustments to the positioning of
the six (6) Mount Plates, as well as the ends
of the tubes of the cage where they meet
the Mount Plates. You will want to measure
and compare the position of the Mount
Plates on either side in order to achieve
symmetry. Also re-check the positioning
of the cage itself to make sure everything
is still straight, symmetrical, and correctly
centered/positioned all the way around the
Jeep. Finally, tack the ends of the Main Side
Hoops and the B-Pillars to the Mount Plates.
FIGURE 10
FIGURE 10
16. Position the Seat Belt Bar 17 between the
two B-Pillar bars, with the bends toward the
rear of the Jeep. There are laser-etched
locating marks on the B-pillars, but you may
wish to select a custom height/location for the
Seat Belt Bar. If you wish, place one of the
seats back into the Jeep to properly position
this bar in relation to the seat back. Make
sure the Seat Belt Bar is properly positioned
and square, then tack it into place. At this
point all of the main components of the cage
have been tacked together.
18.Drill the four (4) mounting holes through
the floor beneath each A-Pillar Mount Plate,
using the holes in the plates as your drill
guide. Bolt these mount plates down, and
snug up the bolts on the other four Mount
Plates as well.
19.Before welding the cage further, test-fit
any components that will come close to the
cage, such as doors, tops, etc., for proper
clearances. If you need to break any tack
welds and re-position anything in order to
fit around your specific equipment, do that
at this time. If any further adjustments are
made, re-measure all around the entire cage
to ensure everything is still straight, square
and properly positioned.
FIGURE 10
20.Begin finish-welding the cage. Make sure
that welding blankets protect any vulnerable
interior or dash components from weld sparks. Weld as much of each joint as you can with
the cage mounted in the Jeep. Remove the
cage from the Jeep only to finish those welds
you can not reach with it installed. Remember
that welding tends to bend metal slightly, so
keeping everything bolted down for as much
of the welding process as possible will ensure
that the cage does not distort during welding.
21.Add any optional items to the cage, such as
gussets, grab handles, seat Belt bungs, etc.
FIGURE 10
22.Paint or powder-coat the cage. If painting
yourself, thoroughly clean the cage to remove
any residues, then start with a quality selfetching primer, followed by the color paint of
you choice.
23.Re-install the cage into the Jeep and tighten
all hardware.
Congratulations, you have completed the
installation of your Poison Spyder Full Cage Kit!
Page 6
WARRANTY
Poison Spyder Customs™ warranties all of
the products we sell and distribute for one (1)
year from the date of sale. These products will
be free from defects in material and workmanship
under normal installation, and use. Due to the
intended use the powder coat finish is warranted
for ninety (90) days. The finish warranty will not
cover a product if it has been damaged in any
way. Warranty is limited to repair or replacement.
Poison Spyder Customs™ does not offer any type
of labor or shipping allowance and all warranty
claims are subject to inspection by Poison Spyder
Customs™.
At the discretion of Poison Spyder Customs™, the
products in question can be repaired or replaced
when found defective. Prior to any replacement
or repair, written authorization must be obtained
from Poison Spyder Customs™. Failure to contact
us prior to having warranty work preformed will
immediately void all applicable warranties; and it
is then the sole responsibility of the customer to
remit any payment incurred.
The warranty expressed above is the sole
warranty of Poison Spyder Customs™, and any
other expressed or implied warranties are hereby
specifically excluded and disclaimed.
HOLD HARMLESS AGREEMENT
1. In purchasing a Poison Spyder Customs
Product™ I release, waive, discharge and
covenant not to sue Poison Spyder Customs
officers, servants, agents, or employees
(hereinafter referred to as Releasees) from
any and all liability, claims, demands, actions
and causes of action whatsoever arising out
of or related to any loss, damage, or injury,
including death, that may be sustained by
me (or anyone else), any property belonging
to me (or anyone else), whether caused by
the negligence of the releasees or otherwise,
while working on, using or any activity related
to this product.
Page 7
that may be sustained by me (or anyone else),
or any loss or damage to property owned by
me (or anyone else), as a result of using this
product, whether caused by the negligence of
releasees or otherwise.
3. I further agree to indemnify and hold harmless
the releasees from any loss, liability, damage
or costs, including court cost and attorney
fees, that they may incur due to my use of a
this product, whether caused by negligence
of releasees or otherwise.
4. It is my express intent that this Release and
Hold Harmless Agreement shall bind the
members of my family and spouse, if I am
alive, and my heirs assigns and personal
representative, if I am deceased, and shall
be deemed as a release, waiver, discharge,
and covenant not to sue the above named
releasees. I further agree that this Waiver of
Liability and Hold Harmless Agreement shall
be construed in accordance with the laws of
the State of California.
By accepting this product, I acknowledge and
represent that I have read the above Waiver
and Liability and Hold Harmless Agreement,
understand it and accept it voluntarily as my
own free act and deed; no oral presentations,
statements, or inducements, apart from the
foregoing written agreement, have been made;
I am at least eighteen (18) years of age and
fully competent; and I execute this Release for
full, adequate and complete consideration fully
intending to be bound by same.
If you do not agree with the preceding Hold
Harmless Agreement, you may return the product
and receive a full refund. Please, contact a Poison
Spyder Customs™ sales representative and they
will issue a call tag for the product in question.
Once the product has been received by Poison
Spyder Customs™ a full refund will be issued.
2. I am fully aware of risks and hazards connected
with the use of a this product and I elect to
voluntarily engage in such use of this product
knowing that the use may be hazardous to
me and my property. I voluntarily assume full
responsibility for any risks of loss, property
damage or personal injury, including death,

CJ-7 FULL CAGE KIT INSTALL

Transcription

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