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”.
Procedure A)-On ¾” bottom panel, locate 2 angle brackets to position rear mount supports 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 bolt in place using the 1.5” hardware. Insert bolts from outside in.
B)-Locate 2”x4”x9” stud as follows- Draw centerline down the length of 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. Set the 2”x4”x9” stud onto the opposite end of the ¾” plywood base from the rear mounting brackets. Position the eye bolt holes to be centered 4.75” from the front 17.375” edge, 6” from magneto side and 6.5” from clutch side of the 20.5” bottom edges. Secure the2”x4”x9” stud by sinking 8 drywall screws into it through the bottom of the base. Install the 2 eye bolts with 1 thread showing.
C)-Take each ½” panel measuring 19”x19.375” and (using 5 drywall screws) attach two 2”x2”x18.875” studs flush with the 19” edges and centered. Then attach the two 19”x17.375” sides to form a box measuring 19” high x 17.375” wide x 20.5” long. On the top end, 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” studs along 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 drywall screws from the outside in through the plywood. Mark the drywall screws that mount the 2”x2”x13” and 16” studs with a marking pen to indicate what screws to remove when opening the crate. Attach the lid and mark “This Side Up”