Bunk Pod Front Entry Assembly Instructions www.podtime.co.uk enquiries@podtime.co.uk Working House Ltd
How to assemble your pod This step by step guide will show how to assemble your pod(s) on site. It is recommended that two people work on the pod assembly, which will make it easier to manoeuvre larger components into place. First make sure that you have all of the pod components in your assembly space, and familiarise yourself with the below parts list and tools required. Please note you may have some spare parts left at the end, which are supposed to be spares. If you are setting up a bank of connected pods in a space, start with the pod on the right hand side and work to the left. All pods next to each other in a bank share a partition wall. It is recommended that you read through the instructions once in full before starting the build. Parts List: A: Angle Bracket C: 40mm M6 Bolt E: M6 Sleeve G: 50mm M10 Bolt I: M10 Washer B: 22mm M6 Bolt D: 55mm M6 Bolt F: M6 Nut H: M10 Nut J: S Hook L: Hinge Plate N: Switch/Socket P: Adapter R: Extension Leads T: Curtain K: Hinge M: Small Screw O: LED Strip Q: Connectors S: Curtain Rail Required Tools: Small cross head screwdriver Large flat head screwdriver Needle nose pliers 6mm Allen Key Small flat head screwdriver Spanner or socket set
1. Select a rear side panel as shown to the right. Using: - 4 x A - 4 x B - 4 x F Bolt the four angle brackets into place as shown below. Make sure the angle brackets are in the orientation shown in the drawings and that the nuts (F) are on the correct side.
2. Next select another rear side panel as shown to the right. Using: - 4 x A - 2 x B - 2 x F Bolt the four angle brackets into place as shown to the far right. Note that in this case an angle bracket is bolted onto both sides of the sheet as shown. NOTE: If you are only assembling one stand alone pod without building a bank of pods (or if you are assembling the left most pod in a bank), it is only necessary to use 2 brackets (A) on the front face of the panel as shown here (without adding the two brackets to the back face). Also note that some rear side panels have recessed slots in one side (shown above left in green). On this rear side panel, these recessed slots are only required if you are building a bank of pods. If you are building a stand alone pod, or if this is the left most pod in a bank you can use a rear side panel without these recessed slots. 3a. Using the same panel as in step 2, and: - 2 x A - 2 x B - 2 x F Bolt the two angle brackets to the back face of the panel as shown. NOTE: If you are only assembling one stand alone pod without building a bank of pods (or if you are assembling the left most pod in a bank), it is not necessary to carry out this step 3.
3b. You should now have two panels with angle brackets arranged as below. The panel on the right is from step 1 and the panel on the left is from steps 2 & 3.
4. Next select 8 of the slot support components shown below left. Using: - 16 x E Use a big flat head screw driver to screw the sleeves (E) into the recesses in each part as shown below. A large screw driver held upright with slight downward pressure will make it easier to screw the sleeves in squarely. Screw the sleeves in until they are just below the surface of the part. X 8 5. Next select 2 of the back panel components shown below left. Using: - 8 x B Screw the 8 slot supports from step 4 to the rear of the back panels as shown below. X 2
6. The 2 back panels will now slot into the two rear side panels prepared in steps 1-3. As shown below, slot the back panels into position in the rear side panels. Note the rear side panels should be positioned as shown in step 3b. Once the back panels are in place, the structure should stand freely. Now is the time to place the pod into position in the room, if you are assembling a bank of pods this first pod will go to the right hand side of the room. 7. Next select 2 of the support batons shown below. Slide the support batons into the right rear side panel as shown to the right. Note that one of the slots in each support baton is longer than the other, the batons should be slotted in longest slot first.
8. Select a front side panel as shown below. Using: - 8 x A - 8 x B - 8 x F Bolt the eight angle brackets into place as shown to the right. Make sure the angle brackets are in the orientation shown in the drawings and that the nuts (F) are on the correct side.
9. Select 2 of the curtain rail supports shown below left, and: - 4 x C - 4 x F Using the same front side panel from step 8, bolt the curtain rail supports into place as shown below. 10. Select the component shown below left and slide it into the front side panel from steps 8 & 9 as shown below right. 11. Select the 2 components shown to the right and: - 2 x G - 2 x H - 2 x I Bolt these to the assembly from step 10 as shown below.
12. Using the same front side panel assembly, select the components: - 2 x L - 4 x C - 4 x F Bolt the two hinge plates into position as shown. Make sure that each hinge plate is facing in the direction shown. 13. Next slide the front side panel assembly into position as shown below. Also slide another two support batons into the left rear side panel as shown below. Note that one of the slots in each support baton is longer than the other, the batons should be slotted in longest slot first.
14. Next select the component shown below and: - 1 x G - 1 x H - 14 x I - 2 x J Bolt the S-hooks onto the component as shown to the right. The exploded view shows the order that the components should be bolted together. The S-hooks should protrude directly out to the front. 15. Select the component shown below left and slot this into the assembly from step 14 as shown.
16. Select the lower bed base component shown below left. This bed base has four recessed slots on the underside as shown in green. Manoeuvre the lower bed base into position on the support batons as shown below right, it will also slot into position at the front right of the pod. 17. Next select: - 2 x C - 2 x F Bolt the lower bed base into position at the back as shown below. Each bolt will go down through the bed base, through the support baton and through the angle bracket, so it must be positioned correctly. Once the bolts (C) have been dropped into position (this will involve carefully climbing onto the bed base), one person will need to climb under the bed base to fasten the nuts (F).
18. Take the assembly from step 15 and place this underneath the lower bed base - move it around until it is located in the four recessed slots under the bed base as shown below left. Then using: - 1 x B - 1 x C - 2 x F Bolt the front right of the bed base into position as shown below right (bolt B on the right and C on the left in the drawing). 19. Next select the 3 lower shelf components shown to the right, and: - 1 x G - 1 x H - 2 x I Bolt and slot the components together as shown below, allowing some movement in the swing arm.
20. Fit the shelf assembly from step 19 to the pod as shown below left, then using: - 3 x B - 3 x F Bolt the shelf onto the pod as shown below right. 21. Next select the 3 upper shelf components shown to the right, and: - 1 x G - 1 x H - 2 x I Bolt and slot the components together as shown below, allowing some movement in the swing arm.
22. Fit the shelf assembly from step 21 to the pod as shown below left, then using: - 2 x B - 2 x F Bolt the shelf onto the pod as shown below right. 23. Next select the step component shown to the right, and using: - 1 x B - 1 x F Bolt the step to the pod as shown below.
24. Select the upper bed base component shown below left and fit this to the pod as shown below right. Using: - 1 x B - 3 x C - 4 x F Bolt the bed base to the pod in the positions shown below right (the shorter bolt (B) is front right in the drawing). 25. Select another front side panel and 4 curtain rail supports as shown to the right. Using: - 4 x D - 4 x F Bolt the 4 curtain rail supports into position as shown, on either side of the panel. NOTE: If you are building a stand alone pod, or if this is the left most pod in a bank it is not necessary to put the 2 curtain rail supports on the rear side of the panel as shown, and bolts (D) can be replaced with bolts (C).
26. Using the same front side panel from step 25, select: - 4 x A - 2 x B - 2 x F Bolt the 4 angle brackets into position as shown, on either side of the panel. NOTE: If you are building a stand alone pod, or if this is the left most pod in a bank it is not necessary to put the 2 angle brackets on the rear side of the panel as shown. 27. Using the same front side panel, select: - 6 x A - 6 x B - 6 x F Bolt the 6 angle brackets into position as shown, on the rear side of the panel. NOTE: If you are only assembling one stand alone pod without building a bank of pods (or if you are assembling the left most pod in a bank), it is not necessary to carry out this step 27. 28. If you are building a stand alone pod, or the left most pod in a bank select the 2 components shown in box A. If you are in the middle of building a bank of pods, select the 2 components shown in box B. In either case, slot the long component into the front side panel and then rest the smaller component in position on top as shown to the right. A B
29. Using the same front side panel assembly, select the components: - 4 x L - 4 x C - 4 x F Bolt the 4 hinge plates into position as shown on both sides of the panel. Make sure that each hinge plate is facing in the direction shown. NOTE: If you are building a stand alone pod or the left most pod in a bank, you will not need to add the two hinge plates to the rear surface of the panel, and can use bolts (B) instead of bolts (C) in this case. 30. Slot the front side panel into the pod as shown below. You will also need to locate the two smaller slots at the front. Once in position select: - 2 x C - 2 x F Bolt the front side panel into place in the positions shown to the right.
31. Next select 2 of the support beam components shown below and bolt these into place as shown to the right using: - 8 x G - 8 x H - 16 x I 32. Select the two storage door components shown below left, and using: - 4 x K - 8 x M Screw the four hinges into the storage doors as shown.
33. Select two of the door handle components shown to the right and bolt these onto the storage doors as shown using: - 2 x C - 2 x F 34. Position the hinges of both doors onto the hinge plates on the pod and tighten the locking screw on each hinge plate as shown. 35. Select the components: - 2 x S - 2 x T Thread the curtain rails into each curtain and position them in the curtain rail supports as shown to the right. The pod is now completed and ready to use, however if you are adding additional pods to the left, repeat the procedures shown in steps 1-35, except you will find that many of the components are already in place. The order of assembly should be the same though.
Appendix 1 Electrical Wiring NOTE: The two elements to the electrical wiring of the pods are a 12v supply to the LED lights and a 240v supply to the plug sockets. If required the back panel in every pod can be removed from the inside by unscrewing the four mounting bolts. It s best to replace each back panel before unscrewing another one to maintain the structural integrity of the pods. All electrical wiring should be carried out by a qualified electrician. A1. First take the switch and socket components (N), two sets of components will be required per pod for the upper and lower bunks. Take the facia off both the switch and socket, and using: - 2 x N - 8 x M Screw the switch and socket to the back panels of the pods as shown (over the pre-cut holes). You will also need to punch a hole out of the back of the switch and socket for the wires to pass through. Fit the switch and socket components to every bunk in this way. It s better to put the switch above the socket so that any wires plugged into the socket don t get in the way of the light switch.
A2. Fit the sticky back LED light strip (O) under the shelf in each bunk as shown, the light strip should run the entire length of the shelf to the front of the pod. Cut the light strip to length and a connector (Q) can be fitted to the end of the light strip. The connector should then just stick out the back of the pod through the pre-cut hole as shown below in blue. A3. Plug an extension lead (R) into the connector (Q) at the back of each pod. The extension lead will then need to be cut, stripped and wired into the switch at the back of the pod. The other end of the extension lead is then plugged into the Adapter (P). Once all of the LED lights are wired in this way (and the adapter plugged into the mains supply), it should be possible to switch the lights on and off in each individual pod. A4. Finally using 240v cable (not supplied) wire in every plug socket at the back of the pods so that a 240v supply is available in every pod.
Appendix 2 Additional Storage If you have additional storage on top of your pods, this can be fitted as shown below. This can be done after building the pods in full (steps 1-35) so carry out the pod build first before adding the storage. B1. Select the pod roof component shown below left. Note that there are two recessed holes in the pod roof (shown in green), which should always be facing upwards. Using: - 2 x A - 2 x B - 2 x F Bolt the two angle brackets to the underside of the panel in the positions shown in blue. B2. Place the pod roof onto the pod as shown below left. The angle brackets fitted in the previous step B1 should line up with the holes in the sides of the pod as shown below right. If you are assembling multiple pods, carry out steps B1 and B2 for every pod before proceeding to the next step.
B3. Select two of the components shown below left and using: - 2 x C - 2 x F Bolt these components into place as shown. NOTE: If you are building multiple pods in a bank you will need to fit these components into every pod roof and use a longer bolt (D) where this component is used either side of a partition wall (see below right). B4. Bolt the angle brackets attached to the pod roof in step B1 to the pod side panels using: - 2 x B - 2 x F If you are assembling a bank of pods, in some cases you will be bolting an angle bracket onto either side of the side panels using one bolt. If you are assembling multiple pods bolt all of these angle brackets into place in the side panels before proceeding to the next step.
B5. Select one of the below left back storage panel components, and two of the below right side storage panel components. Using: - 4 x A - 8 x B - 8 x F Bolt the panels together as shown below: If you are assembling storage for multiple pods, build as many storage boxes as needed on the floor in front of the pods, and when ready these can be lifted into position on top of the pods. For example the below shows an assembly for four pods:
B6. Select the storage partition component shown below left. Using, - 4 x A - 6 x B - 6 x F Bolt the storage partition in to position as shown below. If you are assembling storage for multiple pods, add the storage partition to each storage compartment as shown below. B7. For each pre-fitted storage partition from B6, select the following components: - 1 x G - 1 x H - 14 x I - 2 x J Bolt the S-hooks onto the storage partition as shown to the right. The exploded view shows the order that the components should be bolted together. The S-hooks should protrude directly out to the front.
B8. Select: - 4 x L - 8 x B - 8 x F Bolt the four hinge plates into position as shown. Make sure that each hinge plate is facing in the direction shown. Note that if you are assembling multiple pods in a bank you will need to bolt some hinge plates (L) onto both sides of the side storage panels, using the longer bolts (C) as shown to the right. If you are assembling multiple pods, bolt all of the hinge plates into position. B9. Select the two storage door components shown to the right, and using: - 4 x K - 8 x M Screw the four hinges into the storage doors as shown.
B10. Select two of the door handle components shown to the right and bolt these onto the storage doors as shown using: - 2 x C - 2 x F B11. Lift the storage assembly from B8 onto the top of the pod(s). If you have assembled a bank of storage compartments it may require a few people to lift the storage compartments into place. Once in position, use: - 2 x C - 2 x F To bolt the storage compartments onto the pods as shown below. If you are assembling multiple pods you will also need to use longer bolts (D) to bolt through any two adjacent storage compartments.
B12. Position the hinges of both doors onto the hinge plates on the side storage panels and tighten the locking screw on each hinge plate as shown. In the case of multiple pods, assemble and fit as many doors as required. Note that the slot in each door will fit over the S-hook so that a padlock can be used to lock each storage compartment. Your pod is now complete and ready to use!