AB A. Installing Lock Pin

AB A1

Raising cover





Raise cover with the button on the dash as per illustration.

AB A2

Un-hooking link





Disconnect the link for the flap.

AB A3

Installing drill fixture

Note!
In this step it is of extreme importance that the drill fixture is installed so that there is full contact between the drill fixture and the gear segment.





Place drill fixture on gear segment.

Looking straight down from above the drill fixture (1), no part of the gear segment should be seen on either side of the drill fixture, ensure fixture is centered, see illustration.

AB A4

Placing shim





Place a shim (2) (e.g washer or equivalent) in the gap between the drill fixture and gear segment assembly.

Use a Vice-grip(R) to secure the drill fixture and shim as per illustration.

AB A5
Read this before drilling hole!





Note!
The material in the gear segment (1) is of a softer grade than the material in the pivot shaft (2). Therefore it is of great importance not to apply too much pressure on the drill while drilling, or to use too high drill speed on the drilling machine. Applying too much pressure may break off the drill bit in the hole.

Hint:
Use a drop of oil when drilling to avoid broken drill bit. If a drop of oil is used, protect the canvas from grease or stains.

Warning!
Eye protection must be worn when drilling.

Note!
Drill only 3.0 mm (1/8") deep hole at a time, and then pull up the drill out of the hole to discharge the metal chips from the drill flute. Repeat sequence until the full 25.0 mm (1") depth is reached. After approximately 10.0 mm (3/8") drilling, the pivot shaft is appearing (2). At this point, apply only light pressure to the drill. This is to allow the drill bit to slowly cut into the harder material of the pivot shaft.

If for any reason the drill bit is broken off in the hole, a drill bit of better quality must be used to drill out the broken drill bit piece (Diamond Head drill bit).

AB A6
Drilling pilot hole using drill fixture





The hole in the gear segment must be 25 mm (1.0") deep.

Measure the thickness of the drill fixture, from the entering hole for the drill bit, to the bottom of where the hole exits the fixture.

Add 25 mm (1.0") to the measurement taken previously (e.g measured distance + 25 mm (1.0"))

Insert a 3.6 mm (9/64" or 0.157") bit into the chuck of the power drill and make a stop on the drill bit with e.g. a piece of tape.

Hint:
Use a shop vacuum cleaner to collect metal shavings while drilling the hole.

Drill hole until the tape on the drill bit touches the bushing of the drill fixture.

AB A7
Enlarging hole

Remove drill fixture. Use the hole as a pilot hole. Take care not to make it deeper. Enlarge the hole with a 4 mm (5/32") drill to fit the lock pin.

AB A8
Installing lock pin





Remove the drill fixture.

Clean off any metal shavings and de-burr if necessary. Install the lock pin flush to the surface of the gear segment.

Reinstall the link for the flap.

Operate the top one full cycle to check function.

Return to the fault tracing and complete the operation.