INSTALLATION INSTRUCTIONS

Transcription

1 CJ-7 FULL CAGE KIT INSTALL 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) 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 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 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.

2 Poison Spyder Customs CJ-7 FULL CAGE KIT INSTALL Page 2 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 8 (1) C-Hoop 10 (2) B-Pillar L&R 11 (1) B-Crossbar 12 (2) C-Pillar L&R 14 (2) Forward Stringer L&R 15 (2) Rearward Stringer L&R 16 (1) Seat Belt Bar 17 (1) Dash Bar 18

3 Poison Spyder Customs CJ-7 FULL CAGE KIT INSTALL Page 3 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. 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. 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. 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 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. 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.

4 Poison Spyder Customs CJ-7 FULL CAGE KIT INSTALL Page 4 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) 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.

5 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 Poison Spyder Customs CJ-7 FULL CAGE KIT INSTALL 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. 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

6 Poison Spyder Customs CJ-7 FULL CAGE KIT INSTALL Page 6 to ensure everything is still straight, square and properly positioned. 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. 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!

7 Poison Spyder Customs CJ-7 FULL CAGE KIT INSTALL Page 7 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. 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, 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.