General Install
Tools Required
- Drill 3/16 bit or #11 bit
- Metal cutting saw or plasma
- Clamps
- Marking pen
- Small disc sander or grinder
- Always wear eye and ear protection
Instructions
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Position the board in place on the existing rail and using a marking pen trace out the openings as a template for cutting out the existing section. (many people cut out windows to maintain extra strength and some have had success by cutting out the entire inner area). It is advised to cut out a minimum of 1/8” wider then the template windows or section so that the underside doesn’t show through after the boards are in place.
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Various models require some of the existing factory installed rivets to be ground to flat or removed entirely so that the replacement boards lay flat. There is an obvious right and left board with the tunnel edge being a straight cut and the outer edge being an angled cut.
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Using a cutting saw or plasma remove the windows or complete inner area that you have marked from your template (CAUTION double check that you are not removing any factory placed support brackets as it is wise to always leave them in place and cut around)
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Clamp the “Better Boards” in position double checking your cut outs. Remove any existing metal that shows through the windows before attaching the boards. Double check that the upper L section mates within 1mm of your tunnel (not on all models). In some cases minor bending of the angle is required to mate tightly to the tunnel. The boards are designed to fit but in some instances minor trimming may be required.
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When satisfied with your cut outs you can now mark, drill your #11 or 3/16 holes, and rivet the boards in place. Your kit comes with steel 3/16 rivets. It is wise to count and separate these rivets to make certain that you have an equal amount for each side. There is no recommended rivet position or placement nor number of recommended rivets to install. Normally 10 to 15 per side is adequate and on some models you can reuse existing factory placements. It is helpful to rivet as high on the L to tunnel section for addition support on many models. Start by riveting the front and working towards the back without skipping a rivet placement. Start on the support L then rivet the board to the existing foot bed.
