Bestop HOSS 42814 User manual

Installation Tips
Before you begin installing the HOSS™ Cart & Cover, read all instructions thoroughly to avoid damage to the product.
It is normal for the fabric to contract and wrinkle when stored in the shipping carton. Within a few days after the installation, the fabric will relax
and the wrinkles will disappear.
Installation Instructions
INSTALLATION TIME SKILL LEVEL
2 Hours 2 - Moderately Easy
TOOLS
HOSS™Door Cart & Cover
Application:
7/16", 3/4" and
9/16"
• Jeep CJ, Wrangler, Wrangler Unlimited Doors
Part Number: 42814
T-50
Hardtop Organized Storage System

HOSS™Door Cart Installation Instructions
Parts List and
Hardware Identification
Caster, Door Cart,
Part Number 409.58,
Qty - 4
Left Divider, Door
Cart, Part Number
413.59, Qty - 5
3/8" x 16 Acorn Nut, Part
Number 410.87, Qty - 4
1/4-20 Hex Nut, Part Number
397.20, Qty - 4
1/4" Flat Washer, Part
Number 266.41, Qty - 4
Rear Strut, Door
Cart, Part Number
412.47, Qty - 1
Angle Leg, Part
Number 412.39,
Qty - 2
1/4-20 x 1.5" Truss Head Screw, Part
Number 410.88, Qty - 4
Rubber Strip, Part
Number 412.43, Qty - 2
Right Divider, Door
Cart, Part Number
413.58, Qty - 5
Door Cart Kit
Long Foam Tube, Part
Number 412.40, Qty - 10
Pan, Door Cart, Part
Number 412.38, Qty - 1
Assemble Dividers - Door Cart
Slide a Long Foam Tube over one
half of each pair of Dividers. Slide
the sleeve up
and around the
bend.Press the
Divider halves to-
gether. Assemble
five (5) Dividers.
Left Divider
Right Divider
Long Foam
Tubes
Locate the Angle Legs and Rear Strut in the parts
kit. Slide the Angle Legs into the ends of the Rear
Strut and align the holes. Install a Door Cart Caster
in each set of holes with a 3/8-16 Acorn Nut. Do not
tighten the nuts at this time.
Install Angle Legs and Casters
on Door Cart Rear Strut
Rear
Strut
Angle Legs
Door Cart
Casters
3/8-16 Acorn
Nuts
Door Cart Cover, Part
Number 487.71, Qty - 1

HOSS™Door Cart Installation Instructions
Install Door Cart Pan
Install Rubber Strips
The maximum load for
the Door Cart is 235
lbs.
Install Dividers in Door Cart
Insert the Dividers into the holes along the sides
of the Cart Pan. The ends of the Dividers should fit
securely into the mounting holes.
Store taller doors toward the back
of the Door Cart with shorter doors
toward the front.
NOTE
Front
Store taller doors toward the back
of the Door Cart with shorter doors
toward the front.
NOTE
Orient the Door Cart Pan on the Door Cart Assembly
so the holes in the lower ledge along the side of the
pan are toward the bottom of the pan in relation to
the holes in the top layer. Align the mounting holes in
the pan with the mounting holes on the Angle Legs
and install a 1/4-20 x 1.5 Truss Head Screw, 1/4"
Washer and 1/4-20 Hex Nut in each hole.
Tighten the Truss Head Screws then tighten the
Acorn Nuts that secure the Casters to the Door Cart.
Holes in bottom
must be lower
than holes in top
1/4-20 x 1.5 Truss
Head Screws
1/4" Washers
and 1/4-20
Hex Nuts
Orient the Rubber Strips along the top of the
mounting ridges, over the heads of the Truss Head
Screws. Center the strips from top to bottom on the
pan. Peel the backing off the strips a little at a time
and press them firmly into place.
Install Rubber
Strips on ridges

HOSS™Door Cart Installation Instructions
Install Door Cart Cover
Secure the doors and other components between
the dividers on the door cart. Drape the cover
over the parts stretching the elastic of the opening
around the components and down to the base of
the cart.
Remove Torx Bolts
Loosen and remove the Torx bolts from the door
hinge. The 2007 – Current Jeep Wrangler requires
a #50 Torx. Earlier Wrangler models may use a
13mm wrench.
Removing your Doors
To avoid costly replacement of parts,
please set aside all nuts, bolts and
other removable parts in a safe place for future
reinstallation.
Disconnect Door Strap / Cable
Disconnect the door restraining strap and any
wiring or cables plugged into the door. Depending
on the door type, you may need to refer to
the installation manual of the door for proper
disconnection.
Remove Door
To avoid injury or damage to the door, gauge the
weight of the door to the available strength provid-
ed. Some doors may need two people to remove.
With both hands, lift the door upward and out of
the hinges. If the door was factory installed, and
you are removing it for the first time, shift the door
slightly back and forth to loosen the excess paint
inside the hinge.
Before installing the cover, make sure
items within the cart are secure.
Remove Bolt
from Bottom
Pull elastic
opening down
Elastic should fit over the base when covering
2007 Wrangler and Wrangler Unlimited Full Doors
BESTOP HARD TOPS SOFT TOPS