By following the steps outlined below, the assembly, installation and adjustment of the steel doors, will be a simple process. Let s start with the Driver Side. Note: Having the hood open makes the job easier. 1. Using a (3/16 ) drill bit, drill out and remove the (2) rivets that hold the plastic floor pan in place to the lower roll tube below the dash. ((Photo 1)) 2. Remove either the (2) 3/8 factory installed bolts, or the (2) 3/8 bolts if either of our windshields is installed from the roll cage, where the upper and lower tube sections connect. This is adjacent to the rubber hood latch strap. 3. Leave the (2) 3/16 steel spacers supplied with either of our windshields in place. Position the Door Hinge Plate over the roll tube and spacers with the windshield tab on the inside. On the windshield tab as well as the door hinge bracket, the top (2) holes are for 2007 models and the bottom (2) holes are for 2006 and older models. Line up the holes and insert both 3/8 x 2 ½ button head bolts and secure with the serrated flange nuts supplied with the windshield. Tighten Securely!! ((Make sure the windshield is in position and the interior mount tabs line up with the holes from the drilled out rivets.)) NOTE: If a Rhinogear windshield is not going to be installed, there will be extra bolts, spacers and nuts provided in the installation hardware kit. INSTALLATION INSTRUCTIONS RH 412 STEEL DOORS
4. Position the Hinge Plates (2) interior mount tabs to line up with the holes from the rivets removed in step #1. Secure the Hinge Plate to the roll tube using the (2) 1/4 x 1 Hex Head Flanged TEK Screws. tighten securely. ((photo 2 & 2A)) 5. On the lower door panel, install the (2) Hinge Plates on the exterior side of the door; push the flange of the hinge tight against the rubber portion of the trim lock bulb seal, the Backer Plate will go on the interior side of the door. Place the black limiter strap bracket on the lower bolt position on the backer plate, of the upper hinge, the two tabs of the bracket will be vertical.
Secure using the (3) per hinge, 1/4-20 x 3/4 stainless steel button head bolts with the stainless flat washers under the bolt heads and the serrated flange nuts. Start all six nuts on the bolts but do not tighten at this time. (Photo 4) 6. Mount the door to the hinge plate. Install the upper half of the door using the (4) ¼ x 20 x ¾ bolts and zinc washers. Tighten these bolts securely. 7. Carefully close the door and align with the roll cage and cab. The bolt holes in the door panel are oversized to allow the door to move on the hinge plate when the bolts are loose. (Also by loosening the 4 bolts holding the door halves together the top half of the door can be adjusted.) Align the door so the rubber bulb seals against the roll cage. ((Due to inconsistencies in the roll cage a slight overlap of the bulbs seals on doors and cab may be unavoidable.)) (Photo 5) When the door is in position tighten the 6 hinge bolts. Try the door several times to check alignment. NOTE: You can now repeat steps #1 through #9 for assembly and installation of the other door. Final adjustments can be made after both doors are in place. NOTE: For installation on 2006 & older vehicles follow step # 8 then after step # 8 move on to step # 12. For installation on 2007 vehicle skip step # 8 and go to step # 9, do not pass go and do not collect 2 cents. 8. Remove the (2) 3/8 factory installed bolts from the roll cage, where the rear upper and lower tube sections connect. Using the (2) 3/8 x 2 1/2 button head bolt provided in the kit, take the Striker Plate, with the Striker Bolt attached and with the (2) steel 3/16 spacers under the plate, install the bolts. Using the serrated flange nuts, tighten, but only finger tight. The striker may need to be moved slightly when the final adjustment is made. ((Photo 3)) 9. Remove the 2 plastic rivets which secure the top of the plastic side panel. ((If you have either of our top and back panel systems installed you will have to remove the bolt that is fastening the plastic side panel and our rear panel together.)) Pull the side panel out to expose the holes in the frame to which it attaches. Drill the rear hole out with a 3/8 drill bit then slide
the (1) ¼ x 20 U-Nut over that rear hole. Do not fasten the side panel at this time. NOTE: See Photos on pages 10, 11 for latch adjustment tips. 10. Position the correct striker attachment (driver side or passenger side) bracket over the roll cage and align the holes with the side panel. Fasten to the frame using one of the plastic rivets in the front hole and (1) ¼ x 20 x 3/4 bolt and flat washer in the rear hole. (Photo 6) 13. Using the Quick release pins and the strap supplied install the limiter strap. (Photo 8) NOTE: THE GOAL IS A TIGHT SEAL WITH SMOOTH LATCH OPERATION. 11. Fasten the striker plate, with the Striker Bolt attached, to the studs in the bracket using the (2) 3/8 flange nuts and washers. Tighten finger tight until final adjustments are made. 12. Striker Adjustment: With the striker plate loosely attached, gently close the door and line up the striker bolt with the latch. The bolt will move up & down and in & out with the striker plate. Loosening the 2 bolts on the front of the latch will allow the latch to move in & out. Loosening the 2 bolts which hold the latch to the door will allow the latch to rotate. Adjust the bolt and latch to form a tight seal with a smooth latch operation. (Photo 7)
One side is done!!! Repeat this on the opposite side. Enjoy Your new Doors
Got heat??? Wide open company inc. 19006 river road grand rapids, mn 55744 218-327-9722 www.rhinogear.us