Wildcat System Instructions

Size: px

Start display at page:

Download "Wildcat System Instructions"

Jesse Randall
6 years ago
Views:

1 Wildcat System Instructions

2 NOTE: Most steps contained in these instructions will need to be repeated on the other side of the vehicle. Prior to assembly of windshield it is necessary to establish what parts are to be assembled according to how much of the Wide Open Company system you plan to use on your Wildcat. If you are just installing the windshield you will need to follow the Stand Alone Windshield manual. If you are installing the wiper or a heater system you will need to install them prior to installing the windshield. If you are installing either the wing windows or the roof panel it is necessary to install an upper windshield bracket and then you would follow the larger instruction manual. Wildcat System Instructions. Photo 1A Install lower windshield brackets with mounting flange to the inside. Slide upper windshield bracket down over front roll cage. A D is laser cut into the bracket to determine driver side Photo 1B Step 1 Install Windshield: (Photo 1A) A. Install the lower windshield brackets. There is a D or P laser cut into the lower windshield brackets determining driver or passenger side. Remove front roll cage bolts, (one side at a time) pry roll cage apart with a screw driver or a ratchet strap from opposite side of vehicle. Then slide the lower bracket into position and replace roll cage bolts. Leave the roll cage bolts loose, there will be a tightening sequence later in the instructions. (Refer to Photo 1B) B. Install upper Windshield bracket. Slide bracket down over the top of front roll cage. Photo 1C Install Center Clamp Bracket C. Install center clamp bracket. (Refer to Photo 1C) Position clamp bracket over top roll bar, line up holes to the windshield bracket. In the front (2) holes use (2) 1/4 x 1/2 BH bolts & 1/4 flat washers, run bolts through clamp, through windshield bracket and

3 secure with 1/4 flat washers and 1/4 thin nylock nut. For the rear holes use (2) 1/4 x 1 BH bolts 1/4 flat washers, put bolts through clamp and then through top of windshield bracket and secure with 1/4 flat washers and 1/4 nylock nuts. (Do Not Tighten at this time) Windshield Positioning Photo 1D Photo 1E Install Side Clamp Brackets D. Install the side clamp brackets. (Refer to Photo 1D) Position the clamp brackets over the roll bar, line up holes to the windshield bracket. In the outer holes use (2) 1/4 x 1/2 BH bolts and 1/4 flat washers. Run the bolts through clamp and into the weld nuts in the windshield bracket. In the inner holes use (2) 1/4 x 1/2 BH bolts and 1/4 flat washers, run through the clamps then through the windshield bracket and secure with 1/4 flat washers followed by 1/4 thin nylock nuts. (Do Not Tighten) E. Windshield Placement (Refer to Photo 1E) Place windshield on vehicle resting on the front of roll cage. Slide windshield down the roll cage until the lower seal of the windshield is sealing along the hood panel. Using (2) 1/4 x 1 1/4 BH bolts with black caps, run through the upper 2 holes in the windshield through slots in upper windshield bracket, secure on the inside with 1/4 flat washers and 1/4 nylock nuts. Using (4) 1/4 x 3/4 BH bolts with black caps run through lower holes in windshield through lower windshield brackets and secure on the back side using 1/4 flat washers and 1/4 nylock nuts. Windshield Tightening Sequence 2nd NOTE: If you are installing a windshield wiper on your windshield you need to install that at this point. Use the instructions that came with the wiper system for this portion. 1st Push Downward & tighten roll cage bolts NOTE: If you are installing a heater you need to install that at this time. Use the instructions that came with the heater system Photo 1F F. Windshield Tightening Sequence (refer to photo 1F) First tighten the lower windshield bracket bolts, then tighten the upper bolts. Next with someone helping have them push down on the lower part of the windshield making sure you get a good seal to the roll cage and tighten roll cage bolts. Now tighten the side and center clamp brackets. NOTE: If you are installing a Top Panel do not tighten the rear bolts on the center clamp bracket.

4 NOTE: If you are not installing the wing windows move on to Step 3. Photo 2C Photo 2A Install latch striker to bracket Remove these two bolts Step 2: Install Wing Windows & Make Door Modifications. A. (Refer to Photo 2A) First remove the door latch striker from original mounting position. Retain bolts and striker they will be installed on the new striker bracket later in the instructions. New Striker Bracket C. Install new striker bracket. (Refer to Photo 2C) Using (2) 1/4 x 3/4 BH bolts and 1/4 flat washers, run bolts through slotted holes in striker bracket and then through slotted holes in striker brace, secure with (2) 1/4 flat washers and 1/4 nylock nuts on the back side. Using the original striker and bolts install them on the new striker bracket. (Leave bolts loose.) Photo 2D Photo 2B Install P-Clamps Flat side out Install Latch Bracket-Brace B. Install Striker Brace. (Refer to Photo 2B) Using (2) 1/4 x 3/4 BH bolts & 1/4 flat washers run bolts through original striker bracket, through new brace with (2) 1/4 serrated flange nuts securing it on the back side. (Leave Bolts Loose) D. (Refer to Photo 2D) Install (2) P-Clamps on the bar behind the front fenders. Install them with the flat side of the P- Clamp to the outside of vehicle.

5 Photo 2E Photo 2G Remove end cap Upper Mounting Hole Lower Mounting Holes E. Install Wing Window Panel. (Refer to Photo 2E) Position panel on vehicle, first bolt the front lower (mid) mounting hole using a 1/4 x 1 BH bolt and black cap, run through panel then through P-Clamp and secure with 5/16 flat washer and 1/4 nylock nut on inside. On the lower mounting hole use a 1/4 x 1 BH bolt and black cap, run through panel then through P-Clamp and secure with 5/16 flat washer and 1/4 nylock nut on inside. The upper mounting hole could use 2 different fasteners. If you are installing a roof panel you would need to use a 1/4 x 1 1/2 BH bolt and cap. If not installing a roof panel you would use a 1/4 x 3/4 BH bolt and cap, secure it with 5/16 flat washer and 1/4 nylock nut on inside. (Leave bolts loose.) Photo 2F Remove theses 3 bolts, the latch & plastic panel can be removed. G. (Refer to Photo 2G) Remove (3) bolts from door latch, then remove latch and plastic door panel. Also remove the end cap from the door tube. Photo 2H 4 5/8 1/4 Remover these 5 bolts. H. Cutting door tubing. (Refer to Photo 2H) Wrap tape around tube, measure from end of tube back 4 5/8 make a mark. Close door until it is touching wing window panel, the mark on the tubing should be approximately 1/4 from the jam edge of wing window panel. Use a hacksaw or cut off wheel and cut the tubing. Sand the end of the tube and then touch up using a paint marker or spray can then replace the end cap. F. (Refer to Photo 2F) Remove the (5) fasteners in the side restraint door. Pay attention how bolts and washers go, you will need to replace them later in the instructions.

6 Photo 2I Photo 2K Use Flat Washer on this bolt I. Install door latch to new latch bracket. (Refer to Photo 2I) Using (3) 1/4 x 1/2 BH bolts and 1/4 nylock nuts. Also use a 1/4 flat washer on end bolt. Install latch assembly to door tubing K. Install latch assembly on door tubing. (Refer to Photo 2K) Slide latch assembly onto tubing until it aligns with door striker, then close door until latch clicks. Photo 2J Tubing clamp Photo 2L 3rd tighten all striker brace & bracket bolts 2nd tighten exterior wing window bolts 1st tighten these (4) bolts J Install latch bracket to tubing clamps. (Refer to Photo 2J) Using (4) 1/4 x 1/2 BH bolts, (8) 1/4 flat washers (both sides) and (4) nylock nuts. (Leave bolts loose.) L. Door latch and wing window tightening sequence. (Refer to Photo2L) The striker bracket is adjustable both up and down as well as in and out, while tightening keep opening and closing door to get the correct and smooth operation of the door. NOTE: If you are installing a Top panel do not tighten the upper wing window bolt until the Top is in place.

7 Photo 2M NOTE: If you are not installing a back panel move to Step 4. Photo 3A Install P-Clamps to upper rear roll bar. Flat side of P-Clamp to the front of vehicle M. Trim plastic door panel. (Refer to Photo 2M) Using the passenger and driver door templates supplied with the instructions cut along the outer profile of the template. (Leave the end of the door part of the template for correct alignment.) Use tape to secure template to door. Scribe a line across top of the door that needs to be removed. Mark the hole that needs to be drilled then cut the template where the door needs to be cut to length and scribe the plastic. Cover door with 2 masking tape next to cut line, this will protect plastic from getting scratched. Use a jigsaw and cut along line you scribed in the plastic. Step 3: A: Installing back panel. (Refer to Photo 3A) Install (2) P-Clamps to the upper rear roll bar. Position clamps hanging downward with the flat side of the clamp to the inside of vehicle. Photo 3B Photo 2N Bracket Placement Reinstall side nets and tighten all fasteners Drill a 1/8 hole into tube through the hole in the plastic. Use self tapping HH screw & tighten N. Reinstall door plastic and side nets to door tubing. (Refer to Photo 2N) Using the (5) original bolts and washers that were removed earlier, reassemble the doors. Use a 1/8 inch drill bit, drill a hole into the end of tube through the hole that was drilled in the door plastic. Install a self tapping hex head screw to secure the plastic to the tube at the front of the door. B. Lower back panel brackets. (Refer to Photo 3B) Remove the original bolts, position brackets and replace bolts. (Do not tighten until back panel is installed,)

8 Photo 3C Photo 3E C: Install (3) J clips to the holes in the top of the back panel. (Photo 3C) E: Install the plastic filler panel to the back panel using (3) Phillips head screws, screw through filler panel and into the J clips in the back panel. Photo 3D Photo 4A P-Clamp Position Back Panel placement D. Position back panel into place. (Refer to Photo 3D) The P clamps and the brackets are located on the outside of the panel. The top of the panel goes in front of the roll bar. Panel sides fit in the center of the roll cage behind the seat belt brackets. Using (2) 1/4 x 3/4 BH bolts and black caps. Run bolts through lower back panel brackets, through lower holes in back panel, secure with 5/16 flat washers and 1/4 nylock nuts. Using (2) 1/4 x 1 BH bolts and 1/4 flat washers, run bolts through back panel, through P-Clamps securing with 5/16 flat washers and 1/4 nylock nuts on the outside. Tighten all bolts. Step 4: A: Install rear side panels. (Refer to Photo 4A) Install (2) P-Clamps per side. Position clamps with flat side of clamps to the outside of vehicle.

Photo 4B Photo 5B Roof Mounting Bolts Front bolt 1/4 x 2 BH bolt & black cap Rear bolt 1/4 x 1 BH bolt & black cap Roof Mounting Bolts Use a 3/8 x 1 nylon spacer between roof panel and windshield B.

In the front lower mounting hole use a 1/4 x 2 BH bolt and black cap, run bolt through side panel, through 1 x 1 nylon spacer, through the P-Clamp and secure with 5/16 flat washer and 1/4 nylock nut

(Refer to Photo 5B) Position roof panel in place.

9 Photo 4B Photo 5B Roof Mounting Bolts Front bolt 1/4 x 2 BH bolt & black cap Rear bolt 1/4 x 1 BH bolt & black cap Roof Mounting Bolts Use a 3/8 x 1 nylon spacer between roof panel and windshield B. Position Top side panels. (Refer to Photo 4B) Position Top side panels resting on the top of rear fenders. In the front lower mounting hole use a 1/4 x 2 BH bolt and black cap, run bolt through side panel, through 1 x 1 nylon spacer, through the P-Clamp and secure with 5/16 flat washer and 1/4 nylock nut on the inside. For the rear mounting hole use a 1/4 x 1 BH bolt and black cap, run the bolt through side panel, though P-Clamp and secure with 5/16 flat washer and 1/4 nylock nut. B. Position Top Panel. (Refer to Photo 5B) Position roof panel in place. In the front corners use (2) 1/4 x 1 1/2 BH bolts and black caps, run bolts through roof panel and through the 3/8 x 1 nylon spacer then through upper hole in wing window panel and through the windshield bracket then secure using 1/4 flat washer and 1/4 nylock nut. Using (6) 1/4 x 1 BH bolts and black caps finish bolting the rest of the roof panel securing with 1/4 flat washers and 1/4 nylock nuts on the inside. Photo 5A Bolt roof filler panel to the top of windshield Step 5: A. Install Top Panel. (Refer to Photo 5A) Remove windshield center clamp bracket rear bolts, install the Top filler panel to the top of the windshield bracket. Replace center clamp bolts running them through the Top mounting bracket. Using (2) 1/4 x 3/4 BH bolts and 1/4 flat washers, run bolts from inside of vehicle up through outer holes in upper lip of windshield. Through Top filler panel secure all (4) bolts on the top side with 1/4 flat washers and 1/4 nylock nuts. If you have any install questions give us a call at the above number or this number

WOC Mid Size Door Installation

WOC Mid Size Door Installation WOC-10112 Mid Size Door Installation NOTE: If the Mid Size Ranger that you are installing this door system on is a 2010 or newer you will need to remove the sill plates and side nets. If the doors are