www.bigairwaketowers.com
Fusion
Fusion Tower
FusionFusion
Installation and Instruction Manual
Installation and Instruction Manual
Installation and Instruction ManualInstallation and Instruction Manual
Big Air Waketowers
Big Air Waketowers Inc.
Big Air WaketowersBig Air Waketowers
5305 Robert Lee Rd
5305 Robert Lee Rd
5305 Robert Lee Rd5305 Robert Lee Rd
Duncan, OK 73533
Duncan, OK 73533
Duncan, OK 73533Duncan, OK 73533
580
580----252
580580
Toll free: 855
Toll free: 855----252
Toll free: 855Toll free: 855
www.bigair
www.bigairwaketowers
www.bigairwww.bigair
Tower
TowerTower
(Rev A)
Inc.
Inc. Inc.
252----5314
5314
252252
53145314
252----5314
5314
252252
53145314
waketowers.com
waketowerswaketowers
.com
.com.com
IMPORTANT NOTES FOR INSTALLING
YOUR BIG AIR TOWER
• The Fusion Tower is designed to fit a hull between 58” and 103” wide.
Please measure your intended mounting locations to make sure they fall
within this range.
• ALWAYS apply a layer of grease to all bolts before attaching to the joining
connection (some connections will call out blue Loctite).
• To avoid galling or binding, apply a layer of grease onto tubing before
inserting into the H-member. We understand it is a bit messy, but it cleans
up easily.
• If the hull is less than 3/8” thick in base mounting area then the hull will need
to be reinforced. You may use marine grade plywood, aluminum sheeting, or
a fiberglass kit. Contact us for a reinforcement kit.
• Never use the tower to pull inflatables.
• Read over the last page of the manual before drilling.
• Call us toll free if you have any installation questions at 855-252-5314.
Thank you for purchasing Big Air’s Fusion Tower. Installation of the tower is relatively
simple and should take two people 3 to 6 hours. You will need someone to help you
measure and assemble the tower. No special tools are needed other than those listed
below.
Tools Needed
Level
Tape Measure
Variable speed drill
Metric Allen wrench set
Standard Allen wrench set
9/16" Drill Bit
7/16" Drill Bit
Ratchet Strap
Masking Tape
Lithium grease
Metric Wrench set
Standard wrench set
Corner
H-member
Loc # Part # Qty Description
1 BAF-1001 1 H-member
2 BAF-1002 2 Front Leg
3 BAF-1003 2 Rear Leg
4 BAF-1004 4 Front Corner
5 BAF-1005 2 Rear Corner
6 BAF-1006 1 Left Strut
7 BAF-1007 1 Left Strut End
8 BAF-1008 1 Right Strut
9 BAF-1009 1 Right Strut End
10 BAF-1010 4 Hinge Joint
11 BAF-1011 1 Spanner wrench
12 BAF-1012 4 Heim joints
13 BAF-1013 4 Swivels
14 BAF-1014 4 Base mounts
15 BAF-1015 4 backer plate
12 BAF-1016 8 Gaskets
13 BAF-1017 4 Quick release knobs
14 BAF-1018 8 Base bolt - 12mm
15 BAF-1019 8 Nylock 12mm
17 BAF-1021 4 Swivel Bolts
18 BAF-1022 4 3/8" x 1" Bolt
19 BAF-1023 2 3/8" x 1.75" Bolt
20 BAF-1024 12 5/16" x 3/8 Set screw
21 BAF-1025 12 3/8" set screw
22 BAF-1026 4 5/16x3/4 set screw
23 BAF-1027 4 collets
24 BAF-1028 1 Spanner Wrench
Fusion Tower - Parts list
Logo plates
Front Leg
Rear Leg
Base
Base bolt
Gasket
Base plate
14mm nylock
Swivel
Swivel mount bolt
Heim joint
Quick Release Knob
H-member
H-member
threads
Right hand
threads
H-member
Left hand
Rear Corners
Note: shorter
length
Front Corners
Note: longer
length
Step # 1. Decide where to locate your tower
• The Fusion can face either direction based on your preference.
• You can mount your tower anywhere along the boat’s hull where there is access
under the gunnel to install the backing hardware. We recommend you evaluate
what looks best for your boat and your style and were access makes installation
possible. Also, make sure to consider where the tower will rest if you lay it down.
• The front to back stance of the tower is approximately 70 inches long.
.
• Level the floor of your boat. (typically done using your trailer jack)
• Typically it’s best to mark the location for the rear leg mount on the side of the
gunnel and wait on the front leg locations.
• We suggest you use masking tape to cover the area where you will be placing the
mounts. This prevents scratches on the boat’s gel coat. Mark the EXACT
position of all the holes of the base plates.
Step #2: Drill the mount holes
Before drilling holes in your boat, make sure where the holes will go can be accessed
from inside the boat. This typically should not be a problem. If it is, then move the
tower forwards or backwards as necessary.
See our drilling guide at the end of
these instructions.
• Drill a 9/16” hole for each mount.
• You can use your gasket as a guide for your drill center
• Make sure to run your bit in reverse.
• It’s best to drill a 1/4” pilot hole first, then the 9/16” hole.
• If your hull is less than 3/8” thick, you will need to reinforce with additional
aluminum, fiberglass, or marine grade plywood.
Step #3: Install Rear Base Mount Bar Assembly
• Install the base bolts into the base using an allen wrench inserted into the end and secure
tightly (use blue Loctite on threads into the base)
Base Mount
Gasket
Base Bolt
• Secure the bases using a rubber gasket and the aluminum plate retained by the 12mm
nylock nut.
Rectangular Backer
Plate
Nylock
• You can bend the plate with a hammer if needed to match the interior profile of your hull
•
Do this to both rear mount locations.
Quick Release
Step #4: Install Rear Swivels
• Attach the swivel to the base
using the swivel bolt. Do not
tighten excessively.
Base
Heim
Swivel
Step #5: Assemble Tower Structure
(Careful, don’t slide the legs in too far or you may damage the finish of pipe that
will be exposed when installation is finished.)
• We recommend that you mark each corner with a sharpie marker showing the
distance from the end to the corner. This can easily be wiped off later with brake
cleaner.
Corner End
• Install the heim joints half way into the bottom of the legs (make sure to
coat the threads with grease) (by threading half way in, you have some
level adjustment)
• Slide a hinge joint onto each leg as shown in the picture below (note: struts
should not be installed yet)
Rear Corner
Detent pin
Port Strut
Hinge Joint
• Attach the front legs to the front corners using the set screws.
• Attach the rear legs to the rear corners using the set screws and the 5/16” pin.
Note: The rear leg uses a detent pin to help resist rotation from side loads. (The
pull ring should face towards the front leg.)
• Remove the threaded ends from the H-member. (Note, the left/port side threads
are left handed.)
• Slide the left hand threaded caps on to the port/left hand corners.
• Slide the right hand threaded caps on the starboard/right hand corners.
• Slide a collet as shown onto each corner end.
Threaded cap
Collet
• Slide the rear corners into back tube of the H-member (the rear tube has the head
welded on) so that the end of the corner at a minimum passes past the set screw
ring on the H-member.
• Stand the tower up on the ground and use the set screws in the H-member to
secure the corner temporarily.
• Measure the width/distance across between the base mounts. (Do not worry if you
are unable to attain your exact mounting width at this time, you will pull the
structure inward more during installation)
• Install the strut braces
BOW
Port/left
strut end
Port/left
Side strut
Starboard/right
Strut end
Starboard/right
Side strut
Hinge
Joint
• Adjust the tower to match the approximate width of the base mounts.
• Place the tower on the boat connecting at the rear mounts using the quick release
knobs.
• Approximately level the top of the H-member to match the floor. (you will need
to tie the tower to some type of overhead structure during this process)
• Attach a base to the front legs (make sure the front legs are aligned similarly on
each side)
• We recommend pulling the legs slightly forward to create some tension, then
mark the mount locations for the front base mounts.
• Use a gasket to mark drill hole locations for the front mount.
• Drill front mount holes.
• Install the front bases.
• Attach the tower to the bases using the swivels and quick release knobs.
• We recommend that you secure the center of the H-member to the front of the
boat with a rope or strap to help ensure that stays in place and movement is
minimal. The marks on the corners you made with the marker will help you keep
the H-member centered.
• We recommend pulling the corners into the H-member with a ratchet strap. This
preloads the tower. You can do this by looping a ratchet strap around the two
rear legs and pulling them towards each other into the H-member and doing the
same thing with the front legs.) Note…you will have to release the set screws to
do this.
• Before tightening the threaded end caps onto the ends of the H-member:
• you should back off the set screws
• Tap the collets into place.
• Grease the cap threads
• Tighten each end cap using the supplied spanner wrench
• Remember the port/left side threads are left handed.
• We recommend taping the cap to protect the finish from the spanner
wrench.
• If the caps are difficult to thread on, it may be necessary to release the tower on
one side of your boat and lift it upward in the air to remove the preload – this will
allow you to thread the caps on with ease.
• Tighten the end caps using the spanner wrench to approximately 50 ft-lbs. (The
tighter the better)
• Tighten all the set screws
• Double check all bolted connections and set screws to make sure the tower is
secure.
Tip
• If you want the front leg to offer more side to side support, you can tighten the set
screw at the leg to corner connection to make a mark on the connection. Remove
the set screw then drill a small 1/4” divot on the male connector where the set screw
made its mark. This will allow the set screw to secure deeper into the connection.
The tower is now ready for use.
To lay the tower down
:
1. Remove the front leg quick release knobs.
2. Lay the tower backwards.
3. Release the set screws on the front leg connections.
4. Remove the socket head bolts connecting the struts.
5. Pull the front legs free.
6. Reassemble in the reverse order.
Tower laid down towards back
Tower laid down towards front
Trouble Shoots:
1. Apply a thin later of grease to all bolts to prevent galling.
2. Use mineral spirits to remove tape residue after install.
3. If screws become loose, use a thread locker such as loctite on the threads to help
prevent the bolts from vibrating loose (note: when using thread locker, you should not
use grease).
Important Points:
1.
The tower should never be used to pull inflatables or a para-sail.
2.
Check bolts for tightness after each use or road travel.
Drilling Fiberglass
Drilling holes in fiberglass bodies and accessories can be very tricky business. If not done
properly, you can chip off significant pieces of gel-coated surface or cause spider web
cracks.
Trying to cut through gel-coat with the shallow rake angle of a drill bit is what actually
causes the chipping. The cutting edge quickly digs through the layer of gel-coat then lifts
up. The obvious solution is to keep the drill's cutting edge away from the gel-coat. The
following procedure will accomplish this objective.
Step 1 Make a small indent in the surface where the hole is to be made. Use a very sharp
scribe or ice pick. This will prevent the drill from wandering and damaging surrounding
surfaces.
Step 2 Drill the main hole (likely a 3/8” hole) with the drill running in reverse. Let the
drill bit do all the work.
The last and important step is to dress/grind the sharp edge
of the hole exterior to prevent cracks in your gel coat. This
can be done with a “mounted grinding ball/stone”. These
can be purchased at any hardware stone and are used on the
end of your drill to “dress” the hole edge.
Wiring Tips
We recommend wiring the tower while you are installing. However, wiring after
installation can also be done.
Decide which side of the tower you want to run the wire down based on the side your
stereo is on.
Drill ½” holes in the H-member section where you need the wire to come out for speaker
and /or lighting wiring.
Each corner to leg connection has a hole to allow wire through the center.
At the bottom of your rear leg there should be a 3/8 hole for your wire to exit.
We recommend purchasing expandable sleeving to protect and hide your wires. This can
be purchased at a stereo shop or on-line. Below is a link for on-line sleeving.
http://www.mcmaster.com/#9284k3/=r7gre2
Most customers choose to drill a hole through their hull to allow the wires to pass
through. We recommend using the expandable sleeving through this opening also.
Quick release outdoor wiring quick disconnects to pass through your hull can be
purchased directly from Big Air.
Mast/Navigation Light Installation
If you have purchased a Mast/Navigation light, the instructions below offer directions for
installation.
Included in the installation kit are
1) Mast Light, 2) light adapter
plate and 3) two 4mm screws.
1. Remove tow knob cap as
shown in image below by simply
inserting a screw driver into the
side of the cap and rotating it
counterclockwise.
2. Thread on light adapter plate.
3. Install 4 mm screws (as shown in image
below) and use screwdriver to lightly tighten
the adapter plate (making sure not to damage
the screw threads).
4. Disassemble light by twisting black base
counter clockwise from clear housing
*Caution* bulb will become unsecured until
reassembled
5. Attach the black light base using the 4mm
screws. Thread the wires down into the cross
member.
6. Place light bulb in the center of base.
7. The clear portion of the light has tabs that
will lock it back in place.
8. Your light is now installed.
Do you love your Big Air products?
Want to receive a FREE T-shirt*?
Submit a photo and tell us all about it!
We want to see it.
Upload your photo(s) using the following link:
http://www.bigairwaketowers.com/testimonials/submit-photo.php
PHOTO QUALIFICATIONS:
Photo(s) must be .jpeg or .png format
Photo(s) must be at least 600 pixels x 600 pixels
Photo(s) must showcase properly installed Big Air product
Photo(s) must be on the water
HAVE FUN!!! We want to see friends and family as well!
By submitting your photographs, you certify that you own the rights to these photos. You
understand that you will give Big Air Waketowers the right to use and publish your
photos in which way they see fit for advertising, without compensation. Your personal
information will not be sold or rented to any third parties.
*
Accepted photos will be notified. One (1) free t-shirt per order. Additional t-shirts may be purchased.
Returns:
Within 30 days of receiving your order from Big Air Pylons Inc., you may return any
non-custom product. All parts must be in their original condition and packaging, and
cannot be assembled, installed, or damaged. Items that do not meet these criteria
will be returned to you and you will be charged for return shipping (All parts that
have been assembled or installed are not returnable). All returns will incur a 15%
restocking fee. Freight charges are not refundable. If the incorrect part is sent to you
due to our error, we will issue a CALL TAG with our freight company, and send out the
correct part. Any orders refused and returned at time of delivery without an approved RS
number will be charged a 15% restocking charge on entire order and all shipping charges
will not be refunded as well as return shipping charges back to you will be charged. We
are not responsible for any installation errors or labor that occurs as the result of the
installation of any wrong or defective parts.
NOTE: All parts approved for return must be received back to us with all correct
information and RS number issued by us within 30 days of order receipt date or the
return will be cancelled and no credit will be issued.
Damaged and/or Missing Items:
The carrier is responsible for all items during shipping. In the instance that you receive a
damaged part(s) you must call Big Air Pylons Inc. customer service toll free at 855-252-
5314 and state such, as well as file a claim with the UPS 800-PICK-UPS. This must be
done within 24 hours of receiving/not receiving your shipment. Once the damaged part
has been returned to us for UPS/our inspection we will either credit you or ship to you a
replacement part at your choice. Do not install your tower until approval from a Big Air
representative.
Refunds:
Refunds for returns normally take 30 days to process and credit from the date we
receive your return at the warehouse. The manufacturer will then approve your return.
Once the return has been approved and processed, the refund will be credited to the
account you used in the original purchase. You will receive a "credit approved" e-mail
the day you are credited. Please be aware that your bank may take 4-7 business days to
post the credit to your account or credit card. If after 30 days, you have still not received
a credit please e-mail the returns department.
Big Air Pylons Inc. is not responsible for lost, stolen or damaged
packages. All claims for such must be processed through UPS.
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