Assembly Instructions for Laser Sailboat Dolly (with Beach Wheels for 1 Axle & Ramp Wheels with Reversible Axle)

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1 Assembly Instructions for Laser Sailboat Dolly (with Beach Wheels for 1 Axle & Ramp Wheels with Reversible Axle)! IMPORTANT: Before you begin, please read these instructions and check to be sure that all parts and necessary tools are accounted for. Please retain these installation instructions for future reference and replacement part ordering information. Depending on your order, your dolly may be shipped with either ramp wheels or the larger beach wheels. Both sets of instructions are included in this manual.

2 General Safety Instructions: Don t use power tools in damp or wet locations or expose them to rain. Power tools should be double insulated and/or properly grounded. Use Safety Goggles at all times when using power tools to protect against flying debris, and/or dust which could harm your eyes. Secure Work with clamps or vise to hold work when practical. It s safer than using your hands and frees both hands for tool. Metal parts may have sharp edges. Wear protective gloves when assembling metal parts. Use only proper gauge extension cords in good condition. Should you encounter missing parts or any problems while putting your dolly together, please contact us at tech4dollyparts@gmail.com. 2

3 Assembly Instructions for Tech 4 Designs Laser Dolly Parts Supplied: ITEM NUMBER SUPPLIED Axle Frame Assembly (1) Longitudinal Tube Frame Aft Section (1) Longitudinal Tube Frame - Forward Section (1) Handle Frame Assembly (1) Sling Support Assembly (1) Polybag containing: (These parts may be found inserted into (1) appropriate frame holes instead of bagged) (2) 2 ½ x 1/4 Stainless Steel Machine Screws (4) ¼ washers (4) wing nuts Wheels (2) Axle Spindles (fits either 5/8 or 1 wheel hubs) (2) Wheel Clip (2) 5/8 or 1 Large Stainless Washers for Wheels (4) Rubber V-Bow Support (1) Assembly Manual (1) Tools Needed: Phillips Screwdriver 7/16 Wrench Rubber Mallet---Some joints are machined to very close tolerances and gentle tapping may be helpful during assembly. 3

4 Assembly: The Tech 4 Designs Dolly consists of an Axle Frame Assembly, a Longitudinal Frame Assembly (Forward and Aft Sections), a Handle Frame Assembly, Sling Support Assembly and Reversible Axle Spindles. (See Photos 1, 2, 3, 4, & 5). Photo 1-- Axle Frame Assembly Photo 2 Longitudinal Frame Assembly Aft Section Forward Section V Bow Support Photo 3 Handle Frame Assembly Bow Support Bracket 4

5 Photo 4 Sling Support Assembly Photo 5 Reversible Axle Adapter for use with Ramp Wheels with either 5/8 or 1 Hubs For 1 Hubs For 5/8 Hubs Axle Spindle 5

6 Photo 5a Spindles for 1 Beach Wheel Hub Clip Stainless Washer Shoulder Washer Spindle 1. Assemble the Axle Frame first: Locate the Axle Frame (Photo 1) and 2 Axle Spindles (Photo 5 or Photo 5a). Note: If your dolly is equipped with Beach Wheels and 1 Axle, Skip to B below: A. For Ramp Wheels with 5/8 or 1 Hubs: Remove nut and shoulder washer from the end of each 2 screw in the Axle Frame. Pull out both 2 screws and insert large end of Spindle into the Axle Frame so that the two holes of the Frame line up with the two holes in the Spindle (Photo 6). Replace shoulder washer and nut on both 2 screws and tighten securely (Photo 7 & Photo 8). Repeat on the other end the Axle Frame. Nylon Shoulder Washer Photo 6 Photo 7 6

7 Photo 8 Loosely tighten the lock nut. Repeat with the other machine screw, shoulder washer and lock nut. Align the spindle with the axis of the axle frame and tighten both lock nuts. B. For Beach Wheels with 1 Hubs: Remove nut and shoulder washer from the end of each 2 screw in the Axle Frame. Pull out both 2 screws and insert the spindle end with the holes into the Axle Frame so that the two holes of the Frame line up with the two holes in the Spindle (Photo 6a). Photo 6a Photo 7a Replace shoulder washer and nut on both 2 screws and tighten securely (Photo 7a & Photo 8a). Repeat on the other end the Axle Frame. Photo 8a 7

8 2. Attach the Sling Support Assembly: The Axle Frame Assembly has a vertical stub on each end to attach the vertical support frames for the sling assembly. Remove screws and nylon washers from vertical sling supports and slide each vertical support on its respective stub as shown in Photo 9. Photo 9 Photo 10 Each of the vertical support frames has holes on one side that are larger than on the other side. The nylon shoulder washer only fits in the larger holes. Align all the holes and insert the nylon washers (Photo 10 &11) into the larger holes of both vertical frames. Replace the 2 machine screws and secure each with a stainless washer and lock nut. Tighten using a screw driver and 7/16 wrench. (Photos 12). Photo 11 Photo 12 8

9 3. Attach the Handle Frame Assembly to the Forward Longitudinal Frame: Select the handle frame assembly (Photo 3) and the forward longitudinal frame (Photo 2). Remove screws and Nylon Stabilizing Bushing from angled end of the forward longitudinal frame and insert the short stub on the handle frame assembly into this angled end. (Photo 13). Nylon Stabilizing Bushing Photo 13 Photo 14 Note: The holes on one side of the forward longitudinal frame are larger than on the other side. The nylon stabilizing bushing only fits in the larger holes. Align all the holes and insert a nylon stabilizing bushing (Photo 14) into each of the larger holes of the forward longitudinal frame. Replace the 2 machine screws through the holes in the bushings and secure each screw with the stainless washer and lock nut (Photo 15). Tighten using a screw driver and 7/16 wrench (Photo 16). Photo 16 Photo 15 9

10 4. Attach the Aft Longitudinal Frame to the Axle Frame Assembly: The longitudinal frame attaches to the underside of the axle frame assembly. Align the holes in the Aft longitudinal frame with the holes in the middle of the axle frame assembly. Photo 18 Photo 17 Locate polybag containing two 2 ½ screws with four ¼ washers and two wing nuts. Insert both 2 1/2 machine screws with washers and secure with wing nuts and washers (Photo 17 and 18). (Note: These nuts and machine screws can be easily removed to disassemble the dolly for travel to regattas.) 5. Attach the Aft Longitudinal Frame to the Forward Longitudinal Frame: First slide the Rubber V-Bow Support onto the Forward Longitudinal Frame as shown in Photo 19. Use liquid hand soap or dishwashing liquid as a lubricant. The location of the V-Bow support can be determined later to accommodate your particular boat. 10

11 Photo 19 Photo 21 Photo 20 Photo 22 Remove wing nuts, screws and washers from small extension in Aft Longitudinal Frame. Then insert the small inner extension of the Aft longitudinal frame into the Forward longitudinal frame (Photo 20) until the holes are aligned. Replace the screws and washers in the holes and secure with a 1/4 washer and wing nut. (Photos 21 & 22). (NOTE: These nuts and machine screws can be easily removed to disassemble the dolly for travel to regattas.) 6. Attach the Wheels to the Axle Frame: Ramp Wheels with 5/8 or 1 Hubs: On one end of the axle frame, place a stainless steel washer over the spindle (Photo 23), then insert the spindle through the hole in the wheel hub. Place a second stainless steel washer over the spindle and secure the wheel and washers in place with a Wheel Clip inserted through the small hole at the end of the spindle. (Photo 24) Repeat with the other wheel on the opposite end of the axle frame. 11

12 5/8 Washer Photo 23 Photo 24 Beach Wheels with 1 Spindle: On one end of the axle frame, place a stainless steel washer over the spindle (Photo 25). Next insert a white spacer onto the spindle (Photo 26). Insert the spindle through the hole in the wheel hub (Photo 27). Place a second stainless steel washer over the spindle and secure the wheel and washers in place with a Wheel Clip inserted through the small hole at the end of the spindle (Photo 28). Orient the wheel so that the inflating stem is facing outside. (Photo 28) Photo 25 Photo 26 12

13 Photo 27 Photo 28 Congratulations! The Dolly is ready to use. Thank you for purchasing the Tech 4 Designs Laser Dolly. It is manufactured in the USA by American craftsmen and provides a quality product at a reasonable cost. It should provide years of service. Should you encounter any problems while assembling your dolly, please don t hesitate to contact us at tech4dollyparts@gmail.com. Include your daytime contact phone number and we ll get right back to you. 13

14 Parts List Axle Spindle Nylon Shoulder Washer Nylon Lock Nut Eye Strap Wing Nut Nylon Stabilizing Bushing #10 Machine Screw Axle Washer ¼ Washer 2 ½, 2 ¼, 2 Machine Screws Square Axle Tube Frame Wheels with Hubs Square Aft Longitudinal Tube Frame Square Forward Longitudinal Tube Frame (2) Reversible Spindle Assemblies to fit either 5/8 or 1 wheel hubs. Square Handle Tube Frame Assembly Sling Support Assembly Bow Support Bracket Cotter Pins, Cotter Hairpins, or Circular Cotter Pins Nylon Spacer Shoulder Washers Standard Eye Strap 1/4 x 2 Stainless Steel Machine Screws Nylon Stabilizing Bushing 5/8 Large Stainless Washers 1/4 x 2 ½ Stainless Steel Machine Screws 1/4 Stainless Washers 1/4 x 20 tpi Stainless Steel Nylon Lock Nuts Rubber V-Bow Support 1/4 x 20 tpi Stainless Steel Wing Nuts Rev:

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