Drill bits up to 4mm
Counter sink bit
(normal clothes) Iron
1. Check everything first. There are no doubt errors or omissions in these instructions and your requirements may also vary. Use this as a guide and make sure you agree before going ahead.
2. Cut chipboard according to cutting list (or get the man in B&Q to do it – much easier).
3. Drill screw holes using a 2mm drill bit. The hole should be smaller than the screw so that the screw can bite into the chipboard. Proper chipboard screws are important as others can pull out.
4. Counter sink all holes so that the screw head is flush.
5. Cut-out fan holes using the jigsaw or hole cutter.
6. Cut-out cable/pipe notches using the jigsaw.
7. Assemble the main hood according to figure 2. Part D should also be glued down under the screws.
8. Assemble the front lid according to figure 3.
9. Assemble the rear lid according to figure 4.
10. Screw the hinges on the front and rear lids to the centre brace of the main hood according to figure 5.
11. Cut softwood strips to cover inside edges for resting on glass edge and for mounting reflectors to top of lid.
12. Using 20mm chipboard screws, screw softwood strips with bottom edge 30mm up.
13. Varnish the interior with 2 or 3 coats of yacht varnish and allow to dry according to instructions on the tin.
14. Glue screw caps over all exposed screws.
15. Install fans and lights.
Figure 1. almost-orthographic projection.
Figure 2. Exploded assembly diagram of main hood.
Figure 3. Assembly diagram of front lid.
Figure 4. Assembly diagram of rear lid.
Figure 5. Complete assembly diagram.
...some photos to follow...
Edited by MAM, 19 October 2005 - 11:58 PM.