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3
Framing the Hulls
(Recommend two people)
Tools-HEX wrench (provided) and a screwdriver with a
1 /4" head.
Retaining Channel 8
Front Bar Inboard Bolt 3 3/4" 2
Front Bar Outboard Bolt 2" 2
Rear Cross Bar Inboard Bolt 2 1/ 2" 2
Rear Cross Bar Outboard Bolt 2" 2
Lock Nuts for 802-359 Outboard Bolts 4
1. Place the boxes on level ground with the seams
facing up. Cut the bands and open the lid. Remove the
sail, trampoline, rig kits, (two boxes), dagger boards,
rudders, and metal work modular packages. See Figure
1.
1. The dagger board and rudder are in cardboard
sleeves on each side of the hull.
2. Leave the hulls in the end pieces so that they will be
supported in the upright position while being framed.
3. Place the hulls 8 feet apart with the metal trampoline
track facing the inside.
4. Place the backbar across the aft saddles with the
traveler at the back.
5. Locate the bar firmly in the saddles and insert the aft
inboard bolt assembly under the port rail. *See Figure 4.
Start the bolt by hand to insure proper engagement. Do
not start the bolt with the hex wrench as you might cross
thread the internal assembly. If the bolt has trouble
advancing into the bar do the following;
a. Rock the hull with quick movements as you turn the
bolt.
b. Double check the bars alignment with the saddle.
c. Have another person lift and lower the bow as you
turn the bolt.
If you are still having trouble advancing the bolt remove
the back bar from the boat and try the bolt in it. Look for
metal chips or dirt particles inside the bar which could
be hindering the bolt's progress.
*Port refers to left, starboard refers to right.
IMPORTANT
Read this before framing the hulls.
Prior to inserting each crossbar bolt, (Framing the
hull, step 5), apply approximately 1/8th (about one
teaspoon full) of the tube of silicon sealant around
the unthreaded portion of each bolt. This will seal
the area around each bolt and prevent unwanted
water from entering the hull.
6. Install the aft inboard bolt assembly on the starboard
side as described in step 5. It is important that the hulls
be parallel and level at this time. The frame will be very
difficult to attach to the hulls if they are misaligned.
Once the aft inboard bolts are installed, STOP. Do not
install the outboard bolts. This will be done later.
7. Place the front bar across the forward saddles. The
lengthwise track opening should be facing toward the
bows. See Figure 5.
8. With the bar seated firmly in the saddle insert the
forward inboard bolt assembly under the port rail. The
bolt is fitted into the bar by the same procedure as the
aft bolt assemblies.
9. Install the inboard bolt assembly on the starboard
side of the cross bar. If there are any problems
advancing the bolt refer to instructions in step 5A, B, C.
Once the bolts are engaged, STOP. Do not tighten them
down.
Figure 5
Figure 4