Weather Guard 684-5-01, 644-5-01, 644-0-01, 654-5-01, 655-3-01 User Manual
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TRUCK STORAGE SOLUTIONS
SECURING YOUR REPUTATION
ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS
BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.
INSTALLATION MANUAL
STEEL & ALUMINUM SIDE BOX WITH
ALUMINUM & STEEL ALL PURPOSE CHEST
®
PACK RAT® DRAWER UNITS
MODELS
644-X-01, 645-X-01, 654-X-01, 655-X-01, 664-X-01, 665-X-01, 674-X-01, 675-X-01, 684-X-01, 685-X-01
Note: X represents the color code for your model: 0 = Clear | 3 = White | 5 = Black | 52 = Matte Black
NOTICE
Use specic aluminum upt components when installing WEATHER GUARD®
products to aluminum truck beds. Follow additional instructions if mounting
to an aluminum truck bed. There may be left over components depending on
upt.
Any modication 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 modication to, or unintended use of
this product.
WARNING
Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, electric
wires, etc., check under vehicle for locations. All oor 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 Fastener in this area. Holes drilled in this area should be
3/8".
©2015 KNAACK LLC
DANGER
Danger of explosion. Do not use this product for storing or transporting
ammables, explosives, hazardous materials, or hazardous waste, such
as containers of gasoline, 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 modications made to, or unintended use of this product, could
create a hazardous condition that can cause death, serious personal injury or
property damage.
CAUTION
Before marking the leg mounting holes, check inside the box for location of
gas spring housing and components that may obstruct safe drilling. To keep
debris out of your eyes when checking the underside of the vehicle, or when
drilling, always wear protective eyewear.
WEATHERGUARD.COM
WEATHERGUARD.COM
Part No. 24-0292 REV. C ECN 5583 05/15
TOOLS REQUIRED
• Electric Drill
• Bits: 3/8", 1/2"
• Open or Box End Wrench - (2) 1/2", 9/16"
PARTS LIST
(4) 5/16-18
Blind Fastener
(1) Tray with Dividers
(Except Models 644 & 645)
(2) Key
(1)
Installation Tool (4) Floor Mounting Spacer
(8) 5/16"
Flat Washer
• Hammer
• Pencil/Marker
• Oil/Grease
(4) 5/16-18
Nylon Lock Nut (4) Rubber Grommet
• Center Punch
• Tape Measure
(4) 5/16-18 x 1-1/4"
Hex Head Bolt
(1) 5/16-18 x 2-1/4"
Black Oxide Bolt
(4) 5/16"
Lock Washer
ALUMINUM BED UPFIT KIT PARTS LIST - 32-0243
(4)
Vinyl Tape
(1)
Zinc Rich Primer
(8) 1/2" x 1"
Plastic Washer
BLIND FASTENER INSTALLATION
Place a drop of oil on black oxide bolt for lubrication before assembling.
Place the Blind Fastener in the hole and use 1/2" or 7/16" wrench to
tighten black oxide bolt until fastener is fully seated (it will start out hard
and get easier as fastener “bulbs” out).
Make sure the Blind Fastener and Installation Tool do not turn during
installation.
ALUMINUM TRUCK BED INSTALLATION
Coat drilled holes with Zinc Rich Primer. Insert Blind Fastener through one
1/2" x 1" plastic washer. Insert Blind Fastener into drilled hole. Place
second 1/2" x 1" plastic washer through the bottom of the Blind Fastener.
Continue following installation instructions above to install Blind Fasteners.
(4) 11/32" x 7/8"
Plastic Washer
(8) 5/16" x 3/4"
Plastic Washer
Black Oxide Bolt
Flat Washer
9/16" Wrench
Installation Tool
Blind Fastener
©2015 KNAACK LLC
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INSTALLATION INSTRUCTIONS
Note:
• If your truck bed is constructed of
aluminum, use zinc rich primer to coat
drilled holes.
• If the pickup is tted with a plastic
drop-in bed liner, it may need to be
drilled, trimmed, or cut for proper
installation of truck box.
• Truck box cover may not properly latch
until box is fully bolted to truck bed.
• Periodically check tightness of mounting bolts to ensure proper attachment.
• Use touch-up paint on any drilled holes
to prevent oxidation.
• Install boxes with vehicle parked on
level ground.
STEP 1
Locate Box in Truck Bed
Note:
• Fasten truck box directly to bed oor, not bed
liners or mats. A drop of oil or grease should
be applied to both faces of grommets before
tightening the fasteners to prevent grommets
from binding on washers.
Place box in truck bed and center. Check for interference
with box cover open. Select two ribs in truck bed on which
to mount box (preferably outside of frame rails). Measure
from middle of selected rib to truck box end (dimension
“X” in gure above). Transfer dimension “X” to inside of
both sides of truck box. Mark a line 3"-4" from front and
back on inside of truck box.
3"- 4"
Drill 3/8"D holes
3"- 4"
STEP 2
Drill Mounting Holes
Note:
ALUMINUM TRUCK BED INSTALLATION:
Follow additional instructions if mounting to an aluminum truck
bed as explained in the Blind Fastener Installation on page 2.
• For a one person installation, if desired, the box
may be installed using blind fasteners, eliminating the use of nuts and washers on the underside of the bed. In this case, re-drill the 3/8"
holes in the bed with a 1/2" drill bit.
For a regular installation, use a blind fastener in areas
where standard fasteners can’t be used, such as heat
shields and support channels.
Drill 3/8" holes through box and truck bed at marked locations. Install (4) rubber grommets into holes in the box.
FRAME RAILS
"X"
©2015 KNAACK LLC
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