Steps 1-4

Assembly Note

Due to variations and differences in quality of the aluminum extrusion, WCP will install all tube plugs into the ends of the tubing where they are required. We do this to ensure all tube plugs fit correctly. Step 1 can be skipped as it will be completed before shipping.

When installing the 2” x 2” tube plugs, the following illustrations show the maximum amount of bolts that can be added to each tube. We have provided the amount that is necessary for the cart to be assembled correctly and more may be added if desired. Each tube plug only requires two bolts per side as opposed to the three seen in Step 1. Additionally, only four bolts are needed to attach one tube to an adjacent tube.

Step 1

2” x 2” Tube Plug

Slide a 2” x 2” tube plug into the tube. Align the tapped holes on the sides of the tube plug with the clearance holes in the tubing. Install the six #10-32 x 3/8”L BHCS.

Repeat this step on all 2” x 2” tubing that has the same hole pattern on the ends. There will be 33 plugs in total that need to be installed.

Some plugs may not be a slip fit and may need to be tapped in with a mallet. This is due to the inconsistency with the tubing.

1”x1” Tube Plug (1/16” Wall Tubing)

Slide a 1” x 1” tube plug into the tube plug adapter. Then slide both into the tubing. Align the tapped holes on the sides of the tube plug with the clearance holes in the tubing. Install the two #10-32 x 3/8”L BHCS.

Repeat this step on all 1” x 1” x1/16” tubing that has the same hole pattern on the ends. There will be five plugs and adapters in total that need to be installed

Some plugs may not be a slip fit and may need to be tapped in with a mallet. This is due to the inconsistency with the tubing.

1”x1” Tube Plug (1/8” Wall Tubing)

Slide a 1” x 1” tube plug into the tube. Align the tapped holes on the sides of the tube plug with the clearance holes in the tubing. Install the two #10-32 x 3/8”L BHCS.

Repeat this step on all 1” x 1” x1/8” tubing that has the same hole pattern on the ends. There will be ten plugs in total that need to be installed.

Some plugs may not be a slip fit and may need to be tapped in with a mallet. This is due to the inconsistency with the tubing.

Step 2

Place tubing on a flat surface as shown below. All #10-32 rivnuts should be facing up with the 1/4-20 rivnuts in each corner facing down.

Install the four #10-32 x 3/8”L BHCS screws into each tubing plug in the locations shown below.

Assembly for this step will be easier if all components are placed on a table so that there is access to the side holes.

Step 3

Place the MDF Cart Base on top of the aluminum structure from the previous step. The counter bores in the MDF Cart Base will line up with the rivnuts in the tubing. Install all #10-32 x 1.25”L bolts.

DO NOT over tighten the bolts.

Step 4

Install all tubes as shown in the locations shown below. Use four #10-32 x 3/8”L bolts to secure each one in place