AndyMark Climber in a Box User manual

1 1-13-2022
Assembly Guide
Climber in a Box
Creates 1-Stage am-4667 and 2-Stage am-4668

2 1-13-2022
Parts Used:
Component
Product Number
Qty
Product Photo
1 x 1 x .063 30IN Square Tube am-4203-30 1
1.5 x 1.5 x 0.063 30IN Square Tube am-4669-30 1
2.0 x 2.0 x 0.063 30IN Square Tube am-4670-30 1
Hook Assembly (am-4660)
Climber In A Box Hook Plate am-4654 2
1IN 3/8 OD .192ID Aluminum Spacer am-3876 7
10-32 x 1.500 SHCS am-1014 9
10-32 Nylock Jam Nut am-1063 9
1.5” to 1” Bearing Assembly (am-4661)
1.5" Bearing Plate am-4644 2
1.5" 3/8 OD Round Spacer am-1599 4
Spacer, 1/2 OD x .375 ID x .688 IN Long Plastic Spacer am-1611 2
5/16 OD 1.5" long #10 Aluminum Spacer am-1503 2
Climber In A Box Inside Slider Block am-4629 2

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Climber In A Box 1x1 Clamp Slider Block am-4630 2
5/16" OD .875" Long #10 AL Standoff am-1613 2
Constant force spring am-4657 2
5/16" Hardened Steel Washer am-1009 8
608 Bearing am-4456 4
10-32 Nylock Jam Nut am-1063 8
10-32 Jam Nut am-1612 6
10-32 x 2000 SHCS am-1049 6
10-32 x 375 BHCS with Patch am-1588 8
#10 Washer am-1026 6
10-32 x 500 FHCS with Patch am-1505 4
2.0” to 1.5” Bearing Assembly (am-4662)
2.0" Bearing Plate am-4645 2
2.0" 3/8 OD Round Spacer am-1600 4
Spacer, .47 OD x .33 ID x 1.18 IN Long Plastic Spacer am-1610 2
5/16 OD 2.0" long #10 Aluminum Spacer am-1582 2

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Climber In A Box Inside Slider Block am-4629 2
Climber In A Box 1.5x1.5 Clamp Slider Block am-4631 2
Constant Force Spring am-4657 2
5/16" Hardened Steel Washer am-1009 8
608 Bearing am-4456 4
10-32 Nylock Jam Nut am-1063 12
10-32 Jam Nut
am-1612
6
10-32 x 2500 SHCS
am-1024
6
10-32 x 375 BHCS with Patch am-1588 8
#10 Washer am-1026 6
10-32 x 500 FHCS with Patch am-1505 4
1.5” OR 2.0” Winch Assembly (am-4663)
Climber In A Box Winch Plate am-4646 2
1.125IN Bearing Plate am-3722 1
1.5" 3/8 OD Round Spacer OR
2.0” 3/8 OD Round Spacer am-1599/am-1600 5
10' Silver Dyneema Rope
am-4559
1

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10-32 x 2000 SHCS OR
10-32 x 2.500 SHCS am-1049 6
10-32 Nylock Jam Nut am-1063 12
Climber In A Box Winch Spool Half ip-4647 2
500 Hex HD Bearing am-2986 1
10-32 x 500 BHCS am-1512 8
.250 long . 192 ID . 375 OD AL Spacer (2.0 Winch Only) am-4209 2
1.313 long .192 ID . 375 OD AL Spacer am-1601 1

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Step 1: Align Hook Plates (am-4654) and 5
spacers (am-3976) as shown. The hook will be
used as a drill guide so additional spacers and
hardware will be added later.
Assemble Hook
Step 2: Insert a 10-32 x 1.5” SHCS (am-1014)
through both plates and spacers and secure with
10-32 Nylock Jam Nuts (am-1063).
Pre-Assemble Winch Plates
Step 1: Align winch plates (am-4646) and 4 spacers as shown.
Step 2: Loosely add 10-32 screws and nuts (am-1063) to the assembly.
Winch plates will be installed on the outer-most box tube. The winch plate assemblies are also used as
drill guides for the box tubes.
2.0” Box Tube – 2 Stage Assembly
Hook will be installed on the 1.0” box tube. The hook is also used as drill guides for the box tubes.
1.5” Box Tube – 1 Stage Assembly
2.0” Box Tube – 2 Stage Assembly
1.5” Box Tube – 1 Stage Assembly

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Step 1: Align 2.0” tube bearing plates (am-4645) and 4
spacers (am-1600) as shown.
Pre-Assemble 2.0” Bearing Plates (2 Stage ONLY)
Step 2: Loosely add 10-32 screws (am-1024) and
nuts (am-1063) to the assembly.
Step 1: Align 1.5” tube bearing plates (am-4644) and 4
spacers (am-1599) as shown.
Pre-Assemble 1.5” Bearing Plates
Step 2: Loosely add 10-32 screws (am-1049) and
nuts (am-1063) to the assembly.
Leave hardware loose! Bearing plate assemblies will be used as drill guides for the box tubes.
Leave hardware loose! Bearing plate assemblies will be used as drill guides for the box tubes.

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Drill 2.0” Box Tubes (2 Stage Only)
Step 1: Align the flat edge of the bearing plate with
the edge of the Box Tube.
Step 2: Tighten screws to secure assembly.
Step 3: Use a #7 .201” drill bit and drill two holes in the
plate closest to the edge.
Tips for drilling: Keep drill bit straight and perpendicular to the tube surface.
Make sure not to push to hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling.
Step 5: Move the winch plate assembly to the face 90
degrees opposed to the faces with the holes drilled in
the previous step. Use a #7 .201” drill bit and drill in the
center hole on ONE side.
Step 6: Using a step drill bit, open up the hole in
the tube to approximately 1.125” in diameter.
The rope will pass through this hole so make sure
the edges are deburred and smooth.
Step 4: Align the winch plate assembly to the other
end of the tube. Use a #7 .201" drill bit and drill three
holes on both sides. Ensure the offset hole aligns
across the tube.

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Drill 1.5” Box Tubes
Tips for drilling: Keep drill bit straight and perpendicular to the tube surface.
Make sure not to push to hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling.
Step 1: Align the flat edge of the
bearing plate with the edge of the
Box Tube.
Step 2: Tighten screws to secure
assembly.
Step 3: Use a #7 .201" drill bit and
drill two holes on both sides.
Step 4a: Move the bearing plate assembly to the other
end of tube and other face 90 degrees opposed to the
faces with the holes drilled in the previous step. Use a
#7 .201" drill bit and drill three holes on both sides.
For 2-Stage Climbers drill the following additional holes in the 1.5” Box Tubes
Step 4b: Align the winch plate
assembly to the other end of the tube.
Use a #7 .201" drill bit and drill three
holes on both sides. Ensure the offset
hole aligns across the tube.
For 1-Stage Climbers drill the following additional holes in the 1.5” Box Tubes
Step 5b: Move the winch plate
assembly to the face 90 degrees
opposed to the faces with the holes
drilled in the previous step. Use a
#7 .201” drill bit and drill in the
center hole on ONE side.
Step 5c: Using a step drill bit, open
up the hole in the tube to
approximately 1.125” in diameter.
The rope will pass through this
hole so make sure the edges are
deburred and smooth.

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Tips for drilling: Keep drill bit straight and perpendicular to the tube surface.
Make sure not to push to hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling.
Drill 1.0” Box Tubes
Step 1: Align the flat edge of the hook assembly with
the edge of the 1.0” Box Tube. Tighten screws and use
a clamp to secure the hook to the tube.
Step 2: Use a #7 .201" drill bit and drill two holes on
both sides.
Step 3: Move the hook assembly to the other end of
the tube other face 90 degrees opposed to the faces
with the holes drilled in the previous step.Use a #7
.201" drill bit drill bit and drill two holes on both sides.
Step 4: Move the hook assembly up one hole and
secure. Use a #7 .201" drill bit drill bit and drill a third
hole in-line with the first two holes on both sides.

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Assembly
Step 1: Screw the springs (am-4657) into the 1.0” tube
using 10-32 x.375 patch screws (am-1585) and Nylock
Nuts. (am-1063) The head of the screw should be on the
same side as the coil. The screw should be snug, but not
too tight and the spring needs to be parallel to the edges
of the tube.
Step 2: Attach clamp blocks (am-4630) using
10-32 flat head screws (am-1505) and
standoffs
(am-1613). It may be helpful to use a wrench to
hold the standoff in place while inserting the
screw.
Step 3: Tie rope around the bottom standoff using a
secure not. To secure the knot it’s helpful to carefully
melt the knot and end with a lighter.
Step 4: Attach spring and clamp blocks (am-4631) to
the 1.5” tube using 10-32 flat head screws (am-1505)
and nuts.
Step 5: Attach the Bearing Plate Assembly to the top of
the 1.5” Tube using one10-32 x 0.375” Button Head
Cap Screws with thread patch (am-1588), Washers (am-
1026) and Nuts in the lower hole.
Step 6: Insert the 1.0” tube end into the 1.5” tube so
that the springs align with the top holes in the Bearing
Plates.
Warning:Springs
are sharp be careful
when uncoiling and
handling

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Step 9: Assemble the spacers, washers, and bearings through and alongside the spring as shown.
Step 10: Insert a 10-32 x 2” screw through the plates
and assembly and secure with a nylock nut.
Step 11: For the 2-stage climber, insert the end of the
1.5” tube assembly into the 2.0” tube and repeat steps
1-9 to attach the bearings and plates to the 1.5” tube.
Step 7: Carefully insert slider block on each side and
attach with. The Nuts will fit into the pockets in the
slider blocks.
Step 8: Secure Inside slider blocks (am-4629) and
Bearing Plate Assembly to the top of the 1.5” Tube
using 10-32 x 0.375” Button Head Cap Screws with
thread patch(am-1588), Washers (am-1026)
2.0” Bearing Assembly
1.5” Bearing Assembly

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Step 12: Attach the winch plate assembly to the outer stage. tube using 10-32 button head screws and nuts.
Step 13: Insert 10-32 x 2.5” screw through plate, tube and a spacers. This will help guide the rope
through the hole to the spool.
Step 15: Press a bearing into the bearing plate and attach to the plate using 10-32 button head screws and
nuts. Make s
2.0” Winch Atachment
1.5” Winch Atachment
1.5” Winch Rope Guide
2.0” Winch Rope Guide

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Step 18. Add another spacer and secure with 10-32
screw and nut.
Step 19. Add remaining spacers and screws to
complete the hook assembly.
Step 20. Attach hook to 1.0” box tube using 10-32
screws and Nylock Nuts.
Step 17. Secure the rope to the spool and add your
gearbox to the assembly. The narrow sides of the
spool face outwards. The 2-stage climber uses a
0.5”spacer to accommodate a longer rope.-
For more tips and video on how to choose
a gearbox and tie your rope visit our
website.