Place ABS rim onto deck, where you want to cut hole. Trace inside edge
of rim onto deck as a template. Cut hole. Place rim back onto deck,
clamp and drill about 20 - 3/16" holes about 1" to 1.5"
apart. Take rim off and sand deck lightly around the whole circle for
about ½ inch. Run a small bead of silicone sealant around the
whole drilled area, making sure all holes are covered; then place rim
back on. Install each 8-32x1/2" truss phil bolt, one at a time
and tighten with an 8-32 nylock nut using a 9mm wrench. Clean excess
silicone and allow to dry.
Place lid on rim (drill 3/16" hole in lid and use 3/16" shockcord
to tether lid to best area on deck). Begin to install straps. Lay straps
on lid to find appropriate fitting using recessed areas already pressed
on lids. Make sure straps are parallel (measure side to side), drill
out ¼" holes about 1" - 1.5" above the seam line
and in line with the corresponding recesses of the lid.
To install straps, lay strap (1) (starting with the wide side of the
lid), centring the snap buckle and pulling out about 2" of excess
webbing. Fold over both ends of webbing so you have doubled up on the
webbing and in line over the ¼" holds, mark and punch out
holes in webbing (for best results, use hot pencil soldering iron).
Install with bolts and pull tight end of excess webbing. Lay second
strap in line with other one, again centring snap buckle. Pull out an
equal amount of webbing matching it exactly to the first one, and again
folding the ends by doubling overabout 1". Line up holes and mark.
Punch out holes and bolt tight.
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