Medium Van Build Instructions

Body Saw
Scratch awl
90 degree sander
Rotary file
Metric Tape Measure
5/16 Socket
Upper AC Jig
Lower AC Jig
Auto-center-punch
1/8 drill bit
Small step bit

RAM Body Clips

Upper AC Vent A
Lower AC Vent A

Wax and Grease
ASA to Body Glue
One Step Primer
Wool Daubers

• Remove 5 screws that hold the black plastic trim behind the passenger side rear wheel with a 5/16 inch socket
• Pop trim piece off buy pulling from the wheel well opening. Most of the plastic clips will break and that is expected.
• Twist clips 90 degrees and the lower ones will come out. Upper ones can be pried out with a clip removing tool or squezed from the inside and potentially won't break and can then be reused. Toss broken ones and put any that aren't broken in a bag with the screws. Place bag on top of rear tire.
• Mark for lower vent hole with Jig-A. With a scrach awl mark around the inside of the jig. See photo B
• Mark upper vent 170mm from body seam (photo) to the inside of the upper jig. It is located up and down on the van by fitting in the shape of the van body. Using a scratch awl mark around the inside of the jig.
• Drill holes a little bit on the inside of the corners with an 1/8 bit after marking with an auto-center punch
• Drill holes out larger with a step bit right up to or just past the line that you scribed with the jig
• Starting at one of the holes you drilled use the body saw to cut out along the line. It's a snug fit so you are better being up to 1mm past the line then not quite up to it.
• Test fit the 3D printed pieces. If tight sand additional metal off with the 90 degree sander.
• Clean edge that was cut and in about an inch with wax and grease. Get a fresh spot on the paper towel several times to avoid spreading around anything that you are cleaning off.
• Prime with on step primer and a wool dauber. See photo A
• Clean surfaces on 3D printed parts with wax and grease remover. Make sure 100% dry before gluing
• Put a small bead around the surface on the 3d printed vent where it will attach to the body. Once bead is good and with no potential leaks go ahead and press it into the van.
• Using masking tape to hold parts in place while glue dries if they don't seem to be seating well on their own.

Photo A

Photo B

Photo C