RG500 Motor Crate Directions

Tools Required-

table saw, sockets or wrenches in ½”, 9/16” and 5/8”,

5/16” and 3/8” drills, cordless drill with #2 Phillips bit.

Materials Required-

1) box of 100 drywall screws (2” length).

2) right angle brackets with 3” rise on top hole.

4) 3/8”x1.5” carriage bolts with lock nuts and flat washers.

2) 3/8”x3” carriage bolts with 4 flat washers and 2 lock nuts.

7/16”x7” carriage bolt with 2 flat washers and lock nut.

7/16” wood screw eye bolts.

2”x4”x9”L. stud.

sheet 4’x8’x½” plywood cut into 2 parts 19”x17.375”, 1 part 20.5”x17.375” and 2 parts 19”x19.375”.

panel of ¾” plywood cut to 20.5”x17.375”

2”x2”x8’ studs cut into 4 parts 18.875”, 2 parts 16”, 2 parts 13”, 2 parts 12” and 2 parts 9”.

ProcedureA)-On ¾” bottom panel, locate 2 angle brackets to position rear mountsupports 3” high x 3” in from 17.375” end of base x 6” in from20.5” sides.  Drill 4 holes 5/16” dia. for 2 angle brackets and boltin place using the 1.5” hardware.  Insert bolts from outside in.

B)-Locate 2”x4”x9” stud as follows- Draw centerline down the lengthof the stud.  Measure 2” in from each end and mark on centerline.Drill these 2 points with the 3/8” bit to locate the 2 eye bolts.  Setthe 2”x4”x9” stud onto the opposite end of the ¾” plywood basefrom the rear mounting brackets.  Position the eye bolt holes to becentered 4.75” from the front 17.375” edge, 6” from magneto sideand 6.5” from clutch side of the 20.5” bottom edges.  Secure the2”x4”x9” studby sinking 8 drywall screws into it through thebottom of the base.  Install the 2 eye bolts with 1 thread showing.

C)-Take each ½” panel measuring 19”x19.375” and (using 5 drywallscrews) attach two 2”x2”x18.875” studs flush with the 19” edgesand centered.  Then attach the two 19”x17.375” sides to form abox measuring 19” high x 17.375” wide x 20.5” long.  On the topend, attach the two 2”x2”x9” studs centered and flush with the17.375” edges of the box with the two 12” long parts along the19.375” sides.  On the bottom end of the box, fit the 13” studsalong the 17.375” sides and the 16” studs along the remaining19.375” sides.  Place the bottom end onto the ¾” base.  Secure the2”x2”sto the base with drywall screws.  Always run the drywallscrews from the outside in through the plywood.  Mark the drywallscrews that mount the 2”x2”x13” and 16” studs with a markingpen to indicate what screws to remove when opening the crate.Attach the lid and mark “This Side Up”.