WEATHER GUARD 301 User Manual

ASSEMBLY AND INSTALLATION INSTRUCTIONS

PACK RAT® Drawer Units - Model 301 through 338

IMPORTANT

BEFORE YOU BEGIN

Read these instructions and
warnings completely before
installation.

BOLT KIT

Approximate Assembly and Installation time:

1 hour per unit (1.0 hrs.)

Depending on van or truck equipment installation experience.

The trademarked RED PUSHBUTTON is your assurance
of WEATHER GUARD® Equipment quality.

Bolt Kit #32-0115 is provided with
your PACK RAT® Drawer Unit.
Check this bolt kit to be sure the
following parts are included:

Quan. Description

4 5/16-18 x 1" Hex Hd. Bolt
6 5/16-18 x 1-1/2" Hex Head

Bolt

1 5/16-18 x 2-1/4" Black

Oxide Bolt
6 5/16" Lock Washer
10 5/16" Flat Washer
4 5/16-18 Nylon Lock Nut
6 5/16-18 Blind Fastener
1 Blind Fastener Installation

Tool
2 5/16-18 x 3/4" Screw
2 5/16-18 Whiz Lock Nut

DANGER

Danger of explosion. Do not use this product for storing or trans­porting flammables, explosives, hazardous materials, or hazard­ous waste, such as containers of gasoline, gas powered equip­ment, solvents, gun powder, dynamite, propane tanks, acetylene
tanks and cutting torches. This product is only intended and safe
for use in storing and transporting small tools, equipment and
other similar materials. Any modifications made to, or unintended
use of this product, could create a hazardous condition that can

cause death, serious personal injury or property damage.

PARTS LIST

 1 - PACK RAT® Drawer Unit
 4 - Mounting Plates
 1 - Rear Mounting Bracket

 1 - Handle

 Screwdriver, common
 Electric Drill w/ 3/8" & 1/2" Bits
 Ratchet Wrench w/ 1/2" Socket
 1/2" Open or Box End Wrench
 9/16" Open or Box End Wrench

TOOLS REQUIRED

Part No. 24-0144 REV. B ECN 5285 03/13

Housing

Stop Brackets

5/16-18 x 3/4" Hex Hd. Bolt

Drawer

Handle

Front Rollers

5/16-18 x 3/4"
Truss Head Screw

Figure 1. Drawer Removal Instructions

5/16-18 x 1-1/2"
Hex Hd. Bolt

5/16" Lock
Washer

5/16" Flat
Washer

Mounting
Plate

5/16-18 Blind
Fastener

Figure 2. Preferred Installation

5/16-18 Whiz Lock Nut

1/2" Hole

INSTALLATION

INSTRUCTIONS

DRAWER REMOVAL

1. Open the Drawer until it reaches
the internal Stop Brackets.

2. Remove the Stop Brackets from
each upper inside location.

2

3. Put the brackets and bolts into the
drawer for later installation. Install the
Drawer Handle.

4. Carefully pull the drawer com­pletely out of the housing, setting it
aside. Lift out the Front Rollers. You
are now ready to proceed with the
installation.

CAUTION

Some of the larger drawers
would best be handled by
two people, so as not to
cause injury to your person.

Figure 3. Alternate Mounting

PREFERRED INSTALLATION

(see Figure 2.)

5/16-18 x 1-1/2"
Hex Hd. Bolt

5/16" Lock Washer

5/16" Flat Washer

5/16-18 Blind
Fastener

1/2" Hole

NOTE: To prevent rust from occur­ring, touch-up any drilled holes.

1. Place the housing in position.

2. Slide a Mounting Plate into each

open end of the front and rear skids,
but no farther than the leading edge of
the slotted hole in the Mounting Plate.

3. Mark through the hole for drilling.
See Blind Fastener Installation In­structions and cautions before drilling.

WARNING

All floor mounting bolts near
the gas tank area should be
installed from the underside
of the vehicle, to guard
against the gas tank being
punctured in the event of a
collision. This would mean
not using blind fasteners in
this area. Holes drilled in this
area should be 3/8".

4. With blind fasteners installed, se-

cure by placing the Mounting Plate as
you had for marking.

WARNING

The PACK RAT® Drawer Unit
design will carry a generous
amount of heavy cargo. You
must use all four of the
mounting plates; one at each
corner. If this isn't possible,
refer to the Alternate Mount

-ing Instructions. Failure to

` comply could result in serious

personal injury or damage to
your vehicle.

ALTERNATE MOUNTING

NOTE: To prevent rust from occur­ring, touch-up any drilled holes.

1. Place the housing into the position,

and mark through the outer slotted
holes of each skid.

2. Remove the housing and read the
Blind Fastener Installation Instructions
and cautions before drilling each of the
hole locations.

WARNING

All floor mounting bolts near
the gas tank area should be
installed from the underside
of the vehicle, to guard
against the gas tank being
punctured in the event of a
collision. This would mean
not using blind fasteners in
this area. Holes drilled in this
area should be 3/8".

3. With all blind fasteners installed,

secure the housing.

4. Reinstall the drawer to the unit by
reversing the removal steps shown in
Figure 1.

3

5/16-18 x 1-1/2"
Hex Hd. Bolt

5/16" Lock Washer

Center Line of Housing

5/16" Flat Washer

5/16-18 Blind
Fastener

5/16" Lock
Washer

5/16-18 x 1"
Hex Hd. Bolt

5/16" Flat
Washer

1/2" Hole

REAR MOUNT ALTERNATE

NOTE: To prevent rust from occur­ring, touch-up any drilled holes.

1. If space is critical and/or for some

reason you cannot mount the rear in
either the preferred method or use the
Mounting Plates at the rear, you may
use the Rear Mounting Bracket.

2. Locate the center line of the hous­ing and place the bracket flush
against the back and flush to the
floor. If necessary, you may turn the
bracket so the floor flange is under
the rear overhang of the housing. Hole
marking will be more difficult.

1/2" Hole

Rear
Mounting
Bracket

5/16-18 Blind
Fastener

WARNING

All floor mounting bolts near
the gas tank area should be
installed from the underside
of the vehicle, to guard against
the gas tank being punctured
in the event of a collision.
This would mean not using
blind fasteners in this area.
Holes drilled in this area
should be 3/8".

Figure 4. Rear Mount Alternate

4. With blind fasteners installed, fas-

ten the bracket to the floor.

5. Mark and drill holes on the back of
the housing for blind fastener instal­lation.

6. With blind fasteners installed, re­place the housing and secure to the
bracket.

3. Mark only the two floor holes for
drilling. See Blind Fastener Install­ation Instructions and cautions before
drilling.

4

5/16" Lock
Washer

5/16-18 Blind
Fastener

1/2" Hole

5/16" Flat
Washer

5/16-18 x 1"
Hex Hd. Bolt

5/16" Lock Washer

INSET

5/16-18 x 1-1/2"
Hex Hd. Bolt

1/2" Hole

Rear
Mounting
Bracket

5/16" Flat Washer

5/16-18 Blind
Fastener

Figure 5. Stacking PACK RAT®

Drawer Units.

STACKING PACK RAT®

Drawer Units

NOTE: To prevent rust from occur­ring, touch-up any drilled holes.

NOTE: When stacking PACK RAT®
units in an open vehicle, apply seal­ant (local purchase) to drilled holed
in the Drawer Unit bodies.

1. With the lower PACK RAT® unit

properly bolted in place, mount the
Rear Mounting Bracket to the top rear
edge of the unit as shown.

2. As with Figure 4., the bracket will
be mounted to the bottom first.

3. Put the upper PACK RAT® unit in
position on top of the lower and mark
the back mounting holes for blind fas­tener installation.

NOTE: Do not install bolts in the
rear of the upper housing at this
time.

4. With the upper housing in proper

bolting position (with drawer and roll­ers removed), mark through inner two
obround holes in the front mounting
skid for blind fastener installation.

NOTE: See Figure 5. Inset for
installation details. Do not use
outer-most obround holes, fasten­ers would obstruct lower unit
drawer travel.

5. With front blind fasteners installed,

fasten the upper housing to the lower.

WARNING

The PACK RAT® Drawer Unit
design will carry a generous
amount of heavy cargo. You
must use all of the mounting
materials provided as specified.
Failure to comply could result
in serious personal injury or
damage to your vehicle.

5

INSTALLATION PROCEDURE USING BLIND FASTENERS

WEATHER GUARD® PRODUCT
REFINISHING PROCEDURES

WARNING

Prior to drilling, so as not to
cut or puncture fuel tanks, fuel
lines, brake lines, electric
wires, etc., check under vehi­cle for locations.

Place a drop of oil on the black ox­ide bolt before assembling as
shown on right. Place the Blind
Fastener in the hole and use a 1/2
or 7/16 wrench to tighten black hex
bolt until the blind fastener is fully
seated. When setting black hex
bolt, it will start out hard. As the
Blind Fastener bulbs out it will get
easier, until it bottoms out or sets.
Make sure the Blind Fastener and
Installation Tool do not turn during
installation.

Black
Oxide
Bolt

Flat
Washer

9/16
Wrench

All WEATHER GUARD® products are
finished with a polyester powder coat­ing, and it is important to follow these
procedures to get proper adhesion. As
Knaack LLC cannot control the
finishing of the products, the warranty
for WEATHER GUARD® products on
paint is not applicable on refinished
products.

1. Sand the surface to be painted with
180-200 grit sand paper to rough up
the surface. This should be followed
by wet sanding with a 400 grit wet or
dry paper.

2. Wipe down the sanded surface with
ketone based thinner. This removes
the dust and softens the powder coat­ing for better paint adhesion.

3. Wipe sanded area with a tack rag
to remove loose dust and particles
before painting.

Installation
Tool

NOTE: Do not use a lacquer over
the powdered coating.

Blind
Fastener

- NOTICE -

Any modification or unintended use of this product shall immediately void all manufacturers warranties.
Manufacturer disclaims all liability for injuries to persons or property resulting from any modification to, or
unintended use of this product.

WEATHER GUARD® products are protected by one or more of the following trademarks:

U.S. - 842268, 1367500, 1661625, 1663369, 1676545, 1882062, 2228051, 2362167 ; Canada - 282725, 297499;

U.K. - 1400720, 1402476; N.Z. - 296049; Aus. - 761964

Knaack LLC
ATTN: Warranty Claims
420 E. Terra Cotta Avenue
Crystal Lake, IL 60014

If you have any questions, please call toll free

©2013 Knaack LLC

at 1-800-456-7865.

Part No. 24-0144 REV. B ECN 5285 03/13