Hood Tarp Fitting Instructions

1)Rear Adjuster Assembly

a)Check tarp length on body to work out rear adjuster mounting position. On most bodies with a forward set hinge that is recessed into the combing rail, the ideal position for the rear adjuster is in between the rear post and tailgate hinge. This is ideal as the tarp should not finish past the tailgate hinge.

b)When rear adjuster is positioned correctly, affix the rear adjuster to the combing rail using 3/8” self tapping bolts (we recommend drilling 8.5mm holes). Once rear adjusters are fitted record the cable centres from side to side, this is needed for front shaft setup.

2)Front Driveshaft Assembly

a)Bearings / Spacers

i)Bearing spacers can be either 40x40x150 RHS or 50x50x150 RHS and every kit should be installed with no less than 4 bearings and spacers. We recommend the use of 40x40x150 RHS when using a direct drive motor. This allows the correct spacing for the motor bracket to reach the head board without packing.

ii)The two outer bearing spacers must be fitted as close as possible and at maximum 40mm to the outsides of the body. The two inner packers can be evenly spaced between the two outer packers and the centre of the body.

iii)When using a 150 RHS spacer it should be fitted 11mm below the sliding surface, with the bearing centred on the packer (bearing is approximately 140mm in length). From sliding surface to top of bearing block should be 16mm and should be 86mm from sliding surface to shaft centre.

b)Stainless Steel Shaft and Pulleys

i)Shaft provided should be approximately 70mm wider than outside of combing rail width.

ii)The shaft needs to be fitted with all pulleys in the appropriate section and centred to the body with the two 150mm wire pulleys set up to the noted cable centres. The four cap socket head screws on each pulley should be torqued to 25 ft/lbs.

iii)With the shaft centred, one of the bearing grub screws needs to be countersunk into the shaft. Use only a ¼” drill bit, as this provides the best fit for the grub screw.

iv)When the handle drive pulley (v-belt/chain sprocket) is aligned with drive handle, lock down the pulley by countersinking the shaft with a 5/16” drill bit,this provides the best fit for the grub screw. If chain drive, torque the four cap socket head screws to 25 ft/lbs.

3)Drive Handle Assembly

a)Position the drive handle assembly on the lower part of the head board making sure both pulleys are aligned vertically.Once aligned fix to head board with four 10mm bolts.

4)Tarp Fitment

a)Affixing The Front Bow and Sail Track

i)The front bow needs to be fixed to the body as far forward as allowable, but enough so the sail track can be fixed over the front of the head board. The tails of the bow should be bolted to two plates welded to the body. We recommend the use of either 5/16” or 3/8” bolts to fix the bow to the plates (two bolts per side).

ii)With the bow mounted slide the sail track over the spline at the bottom of the hood and fix to the front of the head board with either tek screws or rivets.

b)Running The Cables

i)With tarp pack situated on top of the combing rails, remove the threaded rod from one side only and run 6mm solid core cable through the blocks, around the front 150mm wire pulley and then back to the rear adjuster.

ii)Once the cable has been run around the front and back pulleys and through the blocks, overlap the cables at the lower rear return and clamp off the wires with the supplied wire rope clamps. Make sure the cables are pulled as tight as possible via hand before fixing the clamps. Important!!! Before tensioning by hand, make sure the rear adjuster pulley has full adjustment available.

iii)We recommend the wire rope grips be at minimum 100mm apart and the rear most grip to be approximately 100mm away from the rear adjuster. The rear adjuster requires a 5mm Allen key for tensioning and locking away. The correct amount of tension for the cable should be so that the wire cable provides firm resistance when squeezed between thumb and fingers. Repeat for the other side.

iv)*Note: Can join cables directly behind drive block if space permits.

c)Cable to Drive Block Fastening

i)With both cables run and tensioned make sure tarp pack is fully pushed towards the front of the body. Attach wire rope clamps over cable to be locked away on the drive plate on each side of the block. Repeat for other side. Important!!!When locking cable to drive plate, make sure the two wire cable joining clamps are still spaced 100mm from the rear adjuster.

d)Centreing and Locking Down The Blocks (REQUIRES 2 PEOPLE)

i)Run the drive block out approximately two metres from front and then pull out each bow and evenly space them between the drive bow and the fixed front bow. Go through from drive bow forward and make sure every bow is perpendicular (90) to the combing rail with both blocks bashed flat so there is minimal rocking.

ii)Once all bows are square and blocks are flat, go back to the drive bow and align the cable centres with the front shaft and the rear adjusters. When doing this we use a tape measure and run it from the outside of the cable on one side to the inside of the cable on the other side just behind the drive bow. Split up the difference between cable centres (if there is any) and then knock each drive block in/out evenly to suit. With the blocks set-up to the cable centres, lock down the two drive blocks with two long tek screws each.

iii)Move onto the next bow forward and have one person hold their block with the cable running centred through the bush, the other person can then knock their block in or out in order to achieve the same centred alignment. When this is achieved and the bow is still perpendicular and the blocks flat they can be locked down with one long tek screw per side. Repeat this step for the remaining bows. Double check this once finished to make sure that the cables are running centred through all blocks.

e)Centreing and Locking Down The Tarp

i)With the blocks locked down, go through and centre the tarp between the blocks each side and screw the tarp down with the short tek screws provided. Make sure to lock down the tarp through the eyelets when centred vertically on the bow.