ASSAULT WAKEBOARD TOWER
Contents
1. M12 X 40mm BOLT _5 JM12X A5MMBOLT FORUSEWITHITEMS 3 30 _6 JMI2X875mMBOLT 4 FORUSEWITHITEMS 3 8 JM10X 75mmBUTTONHEAD BOLT 4 FORUSEWITHITEMS 27 9 JMTONVLONLOCKNUT 4 8 FOR USE WITH ITEMS 6 FOR USE WITH ITEMS 3 FOR USE WITH ITEMS 3 FOR USE WITH ITEMS 3 1 28 JLOWERSIDERAILS 2 3 FOR USE WITH ITEMS 16 FOR USE WITH ITEMS 16 FOR USE WITH ITEMS 19 FOR USE WITH ITEMS 30 1 1 1 1 1 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 BOARD RACK PACKAGE PER PACKAGE 2 PACKAGES ARE GENERALY INSTALLED PER TOWER ITEM DESCRIPTION QTY COMMENTS 2 _ 1 Forks gja LOGO PLATE WITH BUNGEE CORD 6 X 20mm BOLT FOR USE WITH ITEMS 1 2 M8 X 16mm BOLT USED TO ATTACH RACK ASSEMBLY TO TOWER GUIDE PWB ASSAULT 004 HOLLY i WAKEBOARDING PRODUCTS STEP 1 M12 SPLIT The mounting feet will need to be assembled to the side LOCK WASHERS rail fittings followed by attaching them to the side rails lt LOWER SIDE RAIL M12 X 45MM x M12 X 40MM AW STEP 2 Tape off all the areas that may potentially come into con tact with the side rails Once the feet are connected to the side rails hold the side rail up to your boat Once the rail is aligned with your windshield use a small piece of tape to mark th2. ASSAULT WAKEBOARD TOWER INSTALLATION GUIDE INSTALLATION SUPPORT GUIDE PWB ASSAULT 004 OCA l WAKEBOARDING PRODUCTS IMPORTANT INFORMATION This Aerial wakeboard tower fits motor boats with 76 108 inch wide beam widths This measurement is taken from the Port to Starboard mounting points Do not fold the tower without having the top section securely fastened to the side sections with the fasteners provided Lubricate the telescopic side section tubes that slide in and out of the top section during instal lation We recommend using a light grease to help the tubes slide together without binding e Donotfold the tower by yourself e not assemble tower on the ground and then try to install it on the boat e not use impact drivers to install any hardware e Torque set screws to 35ft Ibs e Torque shoulder bolts 50 ft lbs e Torque tower foot all thread to 65 ft lbs e We recommend using red Loctite threadlocker on the threads of all fasteners that will be adjusted while lowering or raising the tower e Check the top section for burr s before installing side sections to prevent the scratching and marking of tubes Aerial does cover damage caused by burr s during installation e Ifthe area of the deck where the tower will be mounted has a fiberglass thickness of less than inch a backing plate kit must be purchased and installed to provide adequate support e Please leav
3. The clamp located on the base of the switch blade will be connected to the lower side rail We recommend making sure that the clamps on both sides of the tower are located the same distance from the end of the side rail so that your tower looks symmetrical During the clamp installation don t forget to install the rubber clamp col lar s between the clamp and the lower side rail These will be required to allow the clamps fo firmly fasten in place 10 GUIDE PWB ASSAULT 004 STEP 14 612227 WAKEBOARDING PRODUCTS Drilling the top section The X measurement is a great way to make sure that your tow point is the center of your boat To do this measure from the tow point to your rear foot then to your other foot Cover your boat with an old sheet or old cover to make removing the metal shavings easy Someone should hold the top section while you drill Using the pre drilled holes in the top section tube mark the drilling positions the front leg tubes Before making vour marks check to ensure that the tow point is aligned correctly and positioned vertically The tow point should also be positioned on the rear of the top sec tion tube so that the logo plate is facing towards the bow of the boat We then recomend drilling the holes with a smaller drill bit smaller than the 27 64 drill bit to make a pilot hole Following the pilot holes you just drilled use a 27 64 drill bit to create the clearanc
4. e hole for the joining bolts As each hole is drilled we recommend inserting each bolt so that keeps the parts aligned while drilling the next hole GUIDE PWB ASSAULT 004 GLY l WAKEBOARDING PRODUCTS STEP 17 Once all the holes are drilled and all the fasteners are inserted M10 x 75mm Button Head Socket Bolt the nylon lock nuts can be installed and all of the fasteners and nuts can be firmly tight ened You may need to vacuum up the debris and aluminum shavings Note We recommend using Red Loctite Threadlocker when installing these fasteners and any other fasteners that will not require loosening once installed STEP 18 To install the board rack fingers use the socket head cap screws provided and attach the fingers to the diamond shaped plate This diamond plate will then be installed to the rear switch blade legs MIA Res Once you are happy with your tower installation and all of the fittings are lined up to allow the tower to fold and function correctly it will then be important to firmly lock the fittings in place to prevent any unwanted rotation or loos ening We recommend using threadlocker during this step M6 X 12MM 12 GUIDE PWB ASSAULT 004 HOLLY l WAKEBOARDING PRODUCTS STEP 20 LOWERING THE TOWER Lowering the tower requires at least 2 people Never trailer your boat with the tower in the lowered position Always check to make sure all fasteners are tight and
5. e position of the mounting feet 5 GUIDE PWB ASSAULT 004 OLD l WAKEBOARDING PRODUCTS STEP 4 Once the desired position is achieved place one of the nylon mount washers over the piece of tape and trace around it with a permanent marker Transferring marks from the other side This step is very important After taping the second side of the boat in approximately the same areas as the first side you will need to measure the distance that you marked on the first side of the boat It is best to take measurements from the back of the boat and mark with blue tape Be sure to measure from the same point on both sides GUIDE PWB ASSAULT 004 HOLL i WAKEBOARDING PRODUCTS Drilling Once you have marked your 4 holes check the underside of the deck for wires If necessary you should move the wires out of the way while you drill We recommend drilling a small pilot hole which will keep the 17 32 drill bit from walking mov ing A small rat tail file can be used to ease the edge keep the gel coat from chipping Be careful of wires SMALL 17 32 DRILL BIT COUNTERSINK DAIMETER THROUGH GELCOAT PILOT HOLE Gelcoat GUIDE PWB ASSAULT 004 HOLL l WAKEBOARDING PRODUCTS STEP Install the tower mounts to the boat deck the order shown the diagram Note in the case where the deck of your boat is less than 1 4 thick a reinforcing kit is required to thicken and
6. e the foam wrap on the tower until the installing is complete e Please note that when towing your boat you may notice what appears to be movement in your tower It is important to understand that the boat is also moving on the trailer and that this movement can be visually deceiving e Frequently wash your tower with soap and water e Asrequired use Mothers Mag amp Aluminum polish to restore your tower to its original finish e BE CAREFUL when assembling this product We CANNOT be liable for any burring or scratch ing that may occur when sliding sections in and out of each other e NEVER modify this product any way e NEVER climb stand or ride on this product e NEVER tow watersport tubes or inflatable s with this or any other Aerial Wakeboard Tower e ALWAYS use caution with approaching bridges or overpasses e ALWAYS inspect this product for loose bolts fittings or damage before each use Always carefully CONSULT the user manual for proper installation maintenance and usage Aerial is not liable for personal injury or property damage from the use of this or any other Aerial product GUIDE PWB ASSAULT 004 HOLLY i WAKEBOARDING PRODUCTS EXPLODED VIEW 3 GUIDE PWB ASSAULT 004 WAKEBOARDING PRODUCTS PARTS LIST TOWER PACKAGE ITEM DESCRIPTION COMMENTS QTY 2 25 TOWER JOINT THREADED INCL M6 X 12mm BOLT 2 25 TOWER JOINT THRU HOLE INCL 6 12mm BOLT pecekmount
7. joint This is then followed by attaching the clamp to the lower base using the stainless steel socket head cap screw GUIDE PWB ASSAULT 004 HOLLY i WAKEBOARDING PRODUCTS STEP 11 The lower section of the switch blade can now be assembled to the lower fittings and clamp using the trim washer M12 X 45mm socket head cap bolt and threaded lap joint STEP 12 Insert the front leg hinge joint into the lower section of the front arm repeat for the other side Its important not to completely tighten the fittings as some adjustment will necessary before the installation is complete Before inserting the top section make sure there are no burrs in the top section Someone will need to hold the top section for you as you insert the front arm into the top section and fit the hinge into the side rail IMPORTANT NOTES Lubricate telescopic parts with a light grease before sliding together Grease will not prevent the smaller diameter tube from being scratched by the top section tube during insertion so be very care ful not insert the side section tube any further than the final installation width Once the sides and top section are assembled the fittings that con nect to the ends of the front legs can now be firmly tightened so that they do not rotate STEP 13 The rear switch blades can now be installed by attaching the top switch blade fitting the fitting located on the upper section of the front leg
8. reinforce the deck in the mounting locations FLAT DECK MOUNT ASSEMBLY CURVED DECK MOUNT ASSEMBLY 12 X 75MM MI2X75MM BLACK NYLON WASHER Se BLACK NYLON WASHER mm MOUNT 4 MOUNT NYLON WASHER NYLON WASHER CURVED RUBBER WASHER FLAT DECK L REINFORCEMENT Pars RUBBER WASHER eo Ced ALUMINUM BACKING PLATE DT ALUMINUM BACKING PLATE 4e 4 NYLON LOCK NUT CURVED DECK REINFORCEMENT STEP 8 Measuring from your windshield check the distance to the side rail to make sure both sides are symmetric Ll Te III i 8 GUIDE PWB ASSAULT 004 GLY l WAKEBOARDING PRODUCTS STEP 8 CONTINUED The side rails need to be mounted straight up and down If they are leaning in or out this will cause a problem with the tower when you want to fold it STEP 9 SPLIT LOCK WASHER M6 X 12MM Assembling the Switch Blade Rear Leg THREADED LAP JOINT Start at the top of the switch blade and attach the trim SPLITLOCK WASHER washer shoulder bolt and threaded lap joint M12 X 40MM We recommend assemblying all the blade components before installing the blade on the tower M12 X 45MM M12 X 40 fe SPLIT LOCK WASHER THREADED LAP JOINT 14 0 M10 X 25MM SPLIT LOCK WASHER STEP 10 You will then need to attach the lower base to the thread ed lap
9. secure before using the tower again OPTION A OPTION B DISCONNECT DISCONNECT LOOSEN LOOSEN STEP 21 INSTALLING THE NAVIGATION LIGHT NAVIGATION LIGHT SHIPPED SEPARATELY The navigation light is shipped separately It is designed to be installed the top of the tow point For a clean wiring installation the wires supplied can be passed through the center of the tow point along the inside of the top sec tion and down inside the front leg tube The wires will need to exit the front leg tube just above the fittings and then be passed over the fit tings before entering back into the side rail front tube Finally the wires will exit the side rail front tube just above the mounting foot and then enter the deck of the boat through a hole that will need to be drilled so that thev can be connected to a switch and power source Note The tower is not supplied with pre drilled wiring holes as each customer mav have a different wiring requirement depending on how thev fold their tower or the accessories that thev will mount to the tower www aerialwakeboarding com GUIDE PWB ASSAULT 004
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