Medium Van Build Instructions

3/8 drill
1/8 drill bit
Auto-Center-Punch
Small Step Bit
Body Saw
Heater Hole Template
90 Degree Sander
1/4 Ratchet
10mm Deep Socket
3/8 Ratchet
13mm Socket
3/8 Extension Long

Screw-B (#10 x 1/2 self-drilling pan head)

Heater Bracket

One-Step Primer
Clear High Temp RTV
Wool Dauber

• Clean inside and outside corners of heater bracket with Wax and Grease remover.
• Smear a thick layer of clear high temp RTV over the inside corners of the heater bracket making sure there is good coverage that seals up the bottom of the bracket to the top. Wipe a little RTV on the outside corners as well. Set asside to dry.
• Remove 10mm nut and (2) 13mm bolts from carbon canister bracket that is closer to the driver side of the van. Set nuts and bolts off to the side. Toss Bracket out from under van as it won't be re-used.
• Mark holes using the Heater Bracket Template.
• With Auto-Center-Punch mark inside the corners of the hole you drew with the template. The exact location isn't that important as you can change how deep you go with the step bit to get to the outer line of the hole.
• Mark holes for bracket using the bracket as the template followed by center punching. See photo A
• Drill corner and bracket mounting holes with 1/8 pilot holes
• With small step bit drill out corner holes under the outer part of the hole is up to or a little past the hole you drew with the template.
• With the body saw cut out the hole starting from one corner hole and cutting to the next one
• Clean up edges with 90 Degree Sander so they aren't sharp
• Clean area around hole about one inch around with wax and grease remover. Make sure to flip or change the paper towel a couple of times to prevent just smearing around the dirt.
• Once dry primer using a dauber and the one-step primer. See photo B
• Once primer is dry check to see if RTV is at least skinned over. If it is then go ahead and add mroe RTV to the bottom edge of it and screw it down with 4 Screw-B (#10 Self Drilling pan head)
• Add a little extra RTV around the top and in from the bottom. It is important that this is sealed up very well so if there is any doubt go ahead and add a little more. RTV is annoying to get on your hands so use a glove on the hand you are using the spread it around. See photo C

Photo A

Photo B

Photo C