Gold Crown TM V POCKET BILLIARD TABLE INSTALLATION MANUAL www.brunswickbilliards.com SERVICE DEPARTMENT P.O. BOX 68 BRISTOL, WI 53104 51-905708-000 OCTOBER 2007
NOTE: Please use the instructions in this manual to assemble the tables shown below. Illustrations may be different depending on the table being assembled. Also note that careful handling of all components will assure damage-free assembly. PAGE 2 BRUNSWICK INSTALLATION MANUAL
BASEFRAME AND LEG ASSEMBLY Step #1: Assemble the complete baseframe on the floor, matching the corresponding numbers stamped on the component parts. If floor space is not available go to the leg assembly and assemble the baseframe to the top of the legs. Step #2: Position two cross supports into the side sills, loosely attach with hex head bolts, 1/2"-13 x 5" and flat washers, 1-3/8" O.D. x 9/16" I.D. Step #3: Set the remaining end sills into position with the dowel pins into the matching holes. Attach using hex head bolts, 1/2-13 x 5" and flat washers, 1-3/8" O.D. x 9/16" I.D. With all joints flush tighten securely. (Blind nuts are pre-positioned inside the ends of the end sills.) MATCHING STAMPED NUMBERS SIDE SILL END SILL CROSS SUPPORT END SILL FLAT WASHER, 1-3/8" O.D. X 9/16 I.D. HEX HEAD BOLT, 1/2"-13 X 5" FOOT LEVELER Step #4: Position the two leg assemblies and the stretcher upside down. Step #5: Attach the stretcher to the bottom hole in legs with hex head bolts, 1/2"-13 x 3" and flat washers, 1-3/8" O.D. x 9/16" I.D. (Blind nuts are pre-positioned in each end of stretcher.) 1-3/8" O.D. X 9/16" I.D. FLAT WASHER 1/2"-13 X 3" HEX HEAD BOLT STRETCHER Step #6: Attach the four leg levelers into the bottom of the legs. Thread the levelers all the way into the legs. Carefully turn the legs and stretcher assembly right side up and securely attach the top side of stretcher to the legs with remaining two hex head bolts, 1/2"-13 x 3" and flat washers. BOLT, 1/2"-13 X 3" WASHER, 1-3/8" O.D. Step #7: Position the baseframe assembly over the legs. BRUNSWICK INSTALLATION MANUAL PAGE 3
BASEFRAME AND LEG ASSEMBLY (CONTINUED) FIGURE FOUR Step #9: Secure a metal bracket at each corner of the side sill frames (Figure 4) using hex head bolts, 3/8-16 x 3-1/4", flat washers, 1" O.D., and hex nuts, 3/8-16. Step #10: Secure the brackets to the legs (Figure 4) with hex head bolts, 1/2"-13 x 2" (one per bracket) and washers, 1-3/8" O.D. (Blind nuts are pre-positioned inside the legs.) HEX HEAD BOLT 3/8-16 X 3-1/4" FLAT WASHER 1" O.D. HEX HEAD BOLT 1/2-13 X 2" WASHER, 1-3/8" O.D. HEX NUT 3/8-16 FIGURE FOUR FIGURE FIVE NOTE: When leveling the baseframe, there are four "Quick Set" leveling devices provided with the table for this purpose. Step #11: Position the table in its permanent location by setting it into the "Quick Set" levelers. Do not tighten the hex head Allen set screws at this time. Using a precision level, locate the highest corner of the baseframe. Level the table by rotating the foot levelers as required. FOOT LEVELERS SET SCREWS QUICK SET LEVELERS FIGURE FIVE PAGE 4 BRUNSWICK INSTALLATION MANUAL
SLATE INSTALLATION Step #1: This table has a new patented slate leveling system. Prior to installing the slate, assure that all the hex base levelers are below the top surface of the sills and cross supports. See Step 4 below for their usage. FRAME SLATE CROSS SUPPORT HEX BASE LEVELER Step #2: Placing slate at either end of the table, place an end section of slate on the baseframe. Position slate with the proper overhang as shown in Figure 2. Then add the center and remaining end section of slate. Move the entire slate assembly carefully to correct overhang dimensions. FOOT OF TABLE APPROXIMATELY 2-9/16" OVERHANG ALL AROUND TABLE SLATE AND FRAME APPROX. 2-9/16" BASE FRAME BASE FRAME SLATE BRUNSWICK INSTALLATION MANUAL PAGE 5
SLATE (CONTINUED) Step #3: To attach the slate, drill 3/16" pilot holes for wood screws. Make sure the pilot hole angle matches countersunk hole in slate. Insert two (2) #16 x 3" flat head wood screws into the head and foot end sections of slate and tighten. Then insert the remaining screws, tightening them alternately left and right until all screws are fastened. When done in this manner, slate joints will be tight. RADIUS EDGE Step #4: After the slate has been installed, check the level of the table using a precision carpenter's level or machinist's level. For major levelness corrections, rotate the leveler castings as required. Tighten the Allen head set screw at this time in the Quick Set base. For critical leveling, determine the areas to be adjusted, slightly loosen the slate screw in the area to be adjusted, and using a slot head screwdriver, turn the hex base leveler counterclockwise until adjustments are made. Retighten slate screws. NOTE: In the leveling process, make sure the slate joints are flush. Step #5: Be sure the pocket cutouts in the slate have a smooth radius around the top edge of the cutouts. If necessary, sand around the top edges of each cutout to obtain at least a 1/8" radius. Step #6: With the table completely level, the slate joints and any chips in the playing surface should be filled with wax or "Rock Hard" putty. When dry, scrape off or sand until smooth. Step #7: To make cloth reinforcement pieces, cut a 1" wide strip of cloth from one end of a bed cloth. Cut six pieces of cloth approximately 8" long and apply a strip of cloth to each pocket cutout. Bond strips securely with contact adhesive. 1/8" CLOTH REINFORCEMENT PIECE PAGE 6 BRUNSWICK INSTALLATION MANUAL
ATTACHING BED CLOTH TO FRAMED SLATE Before attaching the billiard cloth, clean slate thoroughly. Step #1: Lay the bed cloth over the top of the slate, nap side up, with the nap running from the head end to the foot end of the table. NOTE: In determining the direction of the nap, run your hand lightly over the surface of the cloth. If it meets resistance, it is going against the nap. Step #2: Leave only enough cloth overhang at the head end and left side to permit tacking into the wood slate frame. Leave the balance of cloth overhang at the foot end and right side. NOTE: Do not spread tacks on the bed cloth. Keep them in a container that slides over the cloth. Step #3: Tack or staple the cloth securely to the wood frame at #1 with two tacks or staples approximately 2" apart. Step #4: Stretch the cloth across the table and tack or staple securely at #2 with two tacks or staples 2" apart. Step #5: Stretch the cloth from #1 to #3 and tack or staple securely into the wood frame at the left side of the table. See Figure B. Step #6: Stretching the cloth across the table from #3 and pulling from #2, tack or staple the cloth at #4. Step #7: On the left side, stretch the cloth tightly from #1 toward the side pocket opening and tack or staple securely at #5. Step #8: Repeat Step 5, stretching the cloth from #3 and tacking or stapling at #6. Step #9: On the right side of the table, grasp the cloth firmly and stretch across the table from #5 and toward the side pocket from #2 and tack or staple at #7. Step #10: Repeat Step 7, stretching from #6 and toward the side pocket from #4 and tack or staple at #8. BRUNSWICK INSTALLATION MANUAL PAGE 7
ATTACHING BED CLOTH TO FRAMED SLATE (CONTINUED) FIGURE FOUR Step #11: At location #9, cut a short slit in the cloth at the edge centered on the side pocket opening. Grasp the cloth firmly above this slit, pull the cloth into the side pocket opening and tack or staple to the wood frame. Complete fastening of the cloth to the side pocket opening, making sure the cloth is tacked or stapled to the wood frame. Step #12: Stretching the cloth tightly across the table from location #9, repeat Step 11 at location #10. FIGURE FIVE Step #13: At the head end of the table, tack or staple the cloth at location #11, maintaining uniform overhang. FIGURE FOUR Step #14: Pull the cloth from location #11 toward location #12 and tack or staple securely along the wood frame, keeping the cloth even along the head end. Step #15: Stretch the cloth firmly from location #11 to the foot end of the table and tack or staple at location #13. Step #16: Stretch the cloth tightly from locations #12 and #13 toward location #14 and tack or staple securely along the wood slate frame. FIGURE SIX Step #17: Tack or staple all of the left side on 2" centers keeping the cloth even along the wood frame. FIGURE FIVE Step #18: Tack or staple the balance of the head end on 2" centers also keeping the cloth even along the wood frame. Step #19: Stretch the cloth tightly toward the foot end of the table, tacking or stapling on 2" centers along the wood frame at the foot end. Step #20: Stretch the cloth tightly across the table to the right side, tacking or stapling on 2" centers all the way along the wood frame at the right side. FIGURE SIX FIGURE SEVEN Step #21: Stretch the cloth into the corner pocket openings and tack or staple to the wood slate frame. Step #22: Trim off excess cloth around the perimeter of the slate. Locate the eighteen (18) rail attach holes and cut clearance holes in the cloth with a sharp knife. NOTE: Occasionally cloth will stretch, leaving wrinkles at the pockets. To retighten, remove apron, one end rail and one side rail. Pull cloth taut, and retack or restaple along the open end and side to restore original tightness. PAGE 8 FIGURE SEVEN BRUNSWICK INSTALLATION MANUAL
ATTACHING RAIL CLOTH CORNER POCKET Step #1: Place cloth on rail with the back side down. The cloth should have equal amount of overhang at both ends of rail and extend 1/2" over the featherstrip groove on the cushion side as shown. Step #2: Except for approximately 3" at end of rail, tap featherstrip down with a tapping block and hammer, starting at center of rail. Stretch cloth tightly toward each end of rail and tap featherstrip down. Step #3: At each end of rail, pull the cloth toward the rubber cushion an additional 3/4". Then tap remainder of featherstrip down. Step #4: Trim the cloth on cushion side of featherstrip along the total length of featherstrip as illustrated. FIGURE FOUR Step #5: Fold the cloth down over front of rail, then using thumb and forefinger as a guide along front edge of the cushion to keep the tapping block at rear edge of featherstrip, tap the featherstrip down flush with rail surface as shown. NOTE: Never try to tap a featherstrip flush with just a hammer as you will surely dent the rail surface behind the featherstrip. FIGURE FOUR FIGURE FIVE Step #6: Turn rail over and at corner pockets fold the cloth over the mitred edge as shown, stretching tightly and working out any wrinkles as you staple three places in area shown. FIGURE FIVE BRUNSWICK INSTALLATION MANUAL PAGE 9
ATTACHING RAIL CLOTH (CONTINUED) FIGURE SIX Step #7: Staple three places along the rear edge of the pocket facing X, then trim off excess cloth at pocket area. Step #8: If rail is an end rail, repeat Step 7 at other corner pocket. Then, starting at center of rails, stretch cloth tightly over cushion and staple at bottom of rail working toward each end. FIGURE SIX FIGURE SEVEN Step #9: Trim excess cloth from bottom of rail flush with edge of cloth relief groove. FIGURE SEVEN SIDE POCKET FIGURE EIGHT Step #10: At side pocket, stretch the cloth tightly over nose of cushion and staple three places as shown. Nose Of Cushion Staple three Places FIGURE EIGHT FIGURE NINE Step #11: Slit the cloth up to the edge of cushion nose as shown. Then firmly pull the small strip to the rear of the cushion and staple at rear of facing. Nose Of Cushion Small Fold Small Strip FIGURE NINE FIGURE TEN Step #12: Hold the small fold in place with thumb and forefinger and firmly hold it down over facing. Then staple at rear of facing and at bottom of rail as shown. Small Fold On Top Of Small Strip Step #13: Trim excess cloth as required. FIGURE TEN PAGE 10 BRUNSWICK INSTALLATION MANUAL
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RAIL ASSEMBLY Step #1: Lay out the rails in their respective locations on a protected surface. All rails sections are marked for easy identification. HEAD RAIL CORNER POCKET CASTING (4 REQ D) RIGHT HAND HEAD RAIL RIGHT HAND FOOT RAIL LEFT HAND HEAD RAIL SIDE POCKET CASTING (2 REQ D) FOOT RAIL LEFT HAND FOOT RAIL Step #2: Attach the six pocket castings. Align the castings with the holes in the rails. Place a 5/16 joint connector, slotted end up, in the existing holes. Align the threaded hole in the connector (rotate with screw driver) with casting screw holes. Then place a 5/16-18 x 1-1/4 hex head screw with 5/16 external tooth lockwasher into the joint connector (four locations per corner casting, two location per side castings). Leave the mounting screws finger tight. Step #3: Place a carpenter s square against the cushions at the corners. Square the corners and tighten the corner casting screws. When tightening these screws, assure the castings are flush with the top of the rail and the outer rail extrusions. 5/16-18 JOINT CONNECTOR CARPENTER S SQUARE 5/16-18 X 1-1/4 HEX HEAD CAP SCREW WITH EXTERNAL TOOTH LOCKWASHER CORNER POCKET CASTING Step #4: Place a straight edge against the rails of both the left and right hand side of the rail. Be certain the rails are straight then tighten the side pocket casting screws on both sides of the table. When tightening these screws, assure the castings are flush with the top of the rail and outer rail extrusions. STRAIGHT EDGE 5/16" JOINT CONNECTOR TYPICAL SIDE POCKET CASTING 5/16"-18 X 1-1/4" HEX HEAD CAP SCREW WITH EXTERNAL TOOTH LOCKWASHER BRUNSWICK INSTALLATION MANUAL PAGE 11
RAIL, APRON, POCKET, BRIDGE RAIL, AND BED SPOT ASSEMBLY Step #1: Position the side aprons, end aprons, and ball storage rack on rails. SIDE APRON HEAD END APRON FOOT END APRON SIDE APRON Step #2: Loosely attach the aprons to rails with hex head machine bolts, 5/16-18 x 2" and 5/16" flat washers. Step #3: Holding corners firmly together, attach angle brackets with four (4) pan head cross recessed tap screws #10 x 3/4". 5/16-18 X 2 HEX HEAD CAP SCREW 5/16 FLAT WASHER #10 X 3/4 PAN HEAD SCREW Step #4: Attach the corner casting using #1/4-20 x 1-1/4 machine screws and 1/4 fender washers. Step #5: Attach the ball storage box trim using #10-24 x 1/2 UNC pan head machine screws and #10 flat washers. Step #6: With this accomplished, go back and securely tighten all apron mounting hardware. BALL STORAGE BOX TRIM CORNER CASTING 1/4 FLAT WASHER #10 FLAT WASHER #1/4-20 X 1-1/4 MACHINE SCREW #10-24 X 1/2 UNC PAN HEAD MACHINE SCREW (4 PLACES) PAGE 12 BRUNSWICK INSTALLATION MANUAL
RAIL, APRON, POCKET, BRIDGE RAIL, AND BED SPOT ASSEMBLY FIGURE FOUR (CONTINUED) Step #7: If assembling a pocket table, the triangle rack may be installed at this time as shown in Figure 1. If table is to be equipped with a gully return, do not attach triangle rack to bottom of ball storage rack. FIGURE FOUR FIGURE FIVE NUT PLATE Step #8: Insert 3/8"-16 x 2-3/4" studs and dome washers up through clearance holes in slate and thread into floating nuts in rails (18 places). With rail and apron assembly properly aligned, tighten securely. To recommended torque of 15 ft/lbs. SLATE FRAME DOME WASHER 3/8-16 X 2-3/4" 3/8-16 FIGURE FIVE FIGURE SIX Step #9: Install side and corner pockets. Place them in castings and carefully fit and trim ends to fit flush with cushion ends. Use a scribe or nail set as a drift pin to help locate casting hole. Use the following hardware per pockets: (2) lockwashers, external tooth #10, and (2) socket head machine screws, #10-24 x 5/8". SOCKET HD. CAP SCREW #10-24 X 5/8" TYPICAL POCKET PAD EXTERNAL TOOTH LOCKWASHER #10 Step #10: Attach bridge rack to baseframe at each side of table using pan head cross recessed tap screws, #8 x 1-1/4". Pilot holes are predrilled for proper location. PAN HD. TAP SCREW #8 X 1-1/4" FIGURE SIX BRUNSWICK INSTALLATION MANUAL PAGE 13
RAIL, APRON, POCKET, BRIDGE RAIL, AND BED SPOT ASSEMBLY (CONTINUED) FIGURE SEVEN Step #11: For drop pocket tables attach the triangle rack to the back of the ball storage box as shown using # 8 X 3/4 pan head tapping screws and #8 flat washer. (Do not attach for a gulley system). BALL STORAGE BOX #8 FLAT WASHER TRIANGLE RACK #8 X 3/4 PAN HEAD TAPPING SCREW FIGURE SEVEN FIGURE EIGHT Step #12: Attach the ball storage rack by positioning under and behind the foot apron, lifting up then pulling down to lock into the pre-attached brackets. BALL STORAGE BOX BRACKET SIDE VIEW FOOT END APRON APRON BRACKET BALL STORAGE BOX FIGURE EIGHT FIGURE NINE SIDE VIEW Step #13: Secure to the end apron using 1/4-20 x 1-1/2 hex head screw and 1/4 flat washer. FOOT END APRON BALL STORAGE BOX 1/4-20 WASHER 1/4-20 x1-1/2 HEX HEAD SCREW FIGURE NINE PAGE 14 BRUNSWICK INSTALLATION MANUAL
RAIL, APRON, POCKET, BRIDGE RAIL, AND BED SPOT ASSEMBLY FIGURE TEN Step #1: Locate and install bed spot for each style of table. (CONTINUED) FOOT SPOT HEAD SPOT POCKET TABLE FIGURE TEN BRUNSWICK INSTALLATION MANUAL PAGE 15
GULLY ASSEMBLY Step #1: Attach the triangle rack to either side of the ball receiver box using (2) #8 flat washers and (2) #8 x 3/4" pan head self tapping screws. MOUNTING CLEAT Step #2: Attach the mounting cleat to the back of the receiver box 1/4-20 x 1-1/2 hex head screw. BALL RECEIVER BOX MOUNTING CLEAT #8 FLAT WASHER #8 X 3/4 PAN HEAD TAPPING SCREW TRIANGLE RACK 1/4 FLAT WASHER 1/4-20 X 1-1/2 HEX HEAD SCREW Step #3: Align and position the ball receiver box cleat with the bottom of the ball storage box cleats and securely attach using 1/4-20 x 1-3/4 hex head screws and 1/4-20 flat washers. Step #4: Attach the ball receiver box center cleat to the bottom of the base frame using #10 x 1-1/4 pan head screw. FOOT END APRON SIDE VIEW BALL STORAGE BOX BALL RECEIVER BOX MOUNTING CLEAT 1/4-20 WASHER 1/4-20 x1-3/4 HEX HEAD SCREW BALL RECIEVER BOX BALL STORAGE BOX #10 x1-1/4 PAN HEAD SCREW 1/4-20 FLAT WASHER 1/4-20 x 1-3/4 HEX HEAD CAP SCREW PAN HEAD TAPPING SCREW BALL RECEIVER BOX PAGE 16 BRUNSWICK INSTALLATION MANUAL
GULLY ASSEMBLY (CONTINUED) FIGURES THREE AND FOUR Step #5: Install wire gullies as shown using round head cross recessed self tapping screws, #10 x 7/8". Place the foot end gully sections through the opening in the ball receiver box and attach to the bottom of the baseframe sill plate. RH Foot Gully Track ATTACHMENT POINT RH Head Gully Track Step #6: Attach head end gully sections in the same manner. LH Foot Gully Track LH Head Gully Track RH Foot Gully Track Base Frame LH Head Gully Track LH Foot Gully Track Base Frame Base Frame #10 Fender Washer Ball Receiver Box Gully Track #10 Fender Washer #10 x1-1/4 Pan Head Tapping Screw #10 x1-1/4 Pan Head Tapping Screw Gully Track FIGURE FOUR BRUNSWICK INSTALLATION MANUAL PAGE 17