FVC TR1105B User manual

PROD
UCT I
MAGE
TR1105B
Transit Rear Door Platform
Installation Guide
FLATLINE VAN CO • [e-mail] • 888-667-5576

All Flatline Van Co products must be properly assembled and secured before attaching to your
vehicle. Improper attachment could result in an automobile accident, and could cause serious bodily
injury or death to you or to others involved. You are responsible for assembling and securing Flatline
Van Co products to your vehicle, checking the mounting points and attachments prior to use, and
regularly inspecting the products for wear and or damage. We always recommend you use a
professional to install any aftermarket accessories to your vehicle. If you have no mechanical
experience and are not thoroughly familiar with the installation procedures, you must have the
product installed by a professional installer or other qualified persons. The responsibility is yours
and must be taken seriously for everyone's safety.
1
FLATLINE VAN CO • [e-mail] • 888-667-5576
thanks.

2
FLATLINE VAN CO • [e-mail] • 888-667-5576
THANK YOU!
ARE YOU EXCITED ABOUT YOUR NEW REAR DOOR PLATFORM? HERE ARE A FEW
THINGS TO DO BEFORE BEGINNING THE INSTALLATION PROCESS--
• PLEASE INSPECT THE PRODUCT TO ENSURE THERE WAS NO
DAMAGE INCURRED DURING SHIPPING.
• IF THERE IS DAMAGE TO REPORT, PLEASE CONTACT OUR
CUSTOMER SERVICE DEPARTMENT AS SOON AS POSSIBLE.
• NEXT, USING THE “PACKAGE CONTENTS” PAGE, CHECK
INVENTORY AND FAMILIARIZE YOURSELF WITH THE PARTS
AND HARDWARE.
• GATHER ALL TOOLS REQUIRED FOR INSTALL.
-RATCHET
-13MM SOCKET
-9/16 BOX WRENCH OR SOCKET
-7/32 HEX KEY ALLEN WRENCH
-POWER DRILL
-3/16” DRILL BIT
-27/64” DRILL BIT
-PLASTIC TRIM PIECE REMOVAL KIT (OPTIONAL)
ESTIMATED INSTALL TIME- 2 HRS
ADDITIONAL HELP IS SUGGESTED FOR A FEW OF THE INSTALL STEPS.
TOOLS
9/16 WRENCH
9/16
9/16 SHALLOW
SOCKET
RATCHET
7/32 ALLEN KEY

PACKAGE CONTENTS
3
FLATLINE VAN CO • [e-mail] • 888-667-5576
REAR DOOR PLATFORM
QTY - 1
LOWER FRAME
BRACE
QTY - 1
DOOR BACKER
QTY - 1
PASSENGER BOTTOM
HINGE BRACKET
QTY - 1
PASSENGER TOP
HINGE BRACKET
QTY - 1
EXTERIOR DRILL
TEMPLATE
QTY - 1
INTERIOR DRILL
TEMPLATE
QTY - 1

HARDWARE
4
FLATLINE VAN CO • [e-mail] • 888-667-5576
3/8 OVERSIZED FLAT WASHER
QTY - 1
3/8-16 FLANGED
NYLON INSERT
LOCKNUT
(MAY BE SUBSTITUTED FOR NUT AND WASHER)
QTY - 8
3/8-16 X 1 FLANGED
HEX HEAD SCREW
QTY - 6
3/8 SCREW BONDED
SEALING WASHER
QTY - 1
3/8-16 X 1.5 FLANGED HEX
HEAD SCREW
QTY - 1
3/8-16 X 1.25 BUTTON
HEAD HEX DRIVE
SCREW
QTY - 1

FLATLINE VAN CO • [e-mail] • 888-667-5576
LET’S GET STARTED!
WE SUGGEST HAVING A HELPING HAND WITH THESE FIRST FEW STEPS TO HELP
SUPPORT THE DOOR!
1. STARTING WITH THE BOTTOM HINGE ON YOUR PASSENGER SIDE DOOR-
MAKE SOME ALIGNMENT MARKS WITH A SHARPIE OR MARKER, AND THEN
REMOVE THE 3 FACTORY BOLTS WITH A 13MM SOCKET. HAVE SOMEONE
SUPPORT THE DOOR FOR YOU AND THEN SWING THE HINGE BACK AS
SHOWN IN FIGURE 2 SO YOU CAN SLIDE THE P2 HINGE BRACKET OVER THE
HINGE. THEN REINSTALL THE FACTORY BOLTS AND SNUG DOWN. CHECK
CLEARANCES BY SLOWLY CLOSING THE DOOR; IF ALL IS CLEAR THEN
TIGHTEN DOWN THE BOLTS.
NOTE- SOME MANIPULATION OF THE BRACKET AND HINGE MAY BE
NECESSARY TO GET THE BRACKET SEATED CORRECTLY ON TOP OF
THE HINGE AND THE HINGE BACK IN PLACE.
2. REPEAT THE SAME PROCESS ON THE UPPER HINGE USING THE P1 HINGE
BRACKET. ENSURE THAT THE DOOR IS SAFELY SUPPORTED AND DOES NOT
TWIST WHEN UNBOLTING THE HINGE. ONCE THE UPPER HINGE BRACKET IS
INSTALLED, TEST DOOR FUNCTION AND MAKE SURE THERE IS NO CONTACT
WITH THE DOOR OR BODY OF THE VAN DURING OPERATION.
5
FIGURE 2
FIGURE 1
FIGURE 3
MAKE
ALIGNMENT
MARKS

FLATLINE VAN CO • [e-mail] • 888-667-5576 6
3. NEXT, YOU WILL NEED TO REMOVE THE INTERIOR DOOR PANEL. WE
RECOMMEND USING SOME PLASTIC PANEL REMOVAL TOOLS (EASILY FOUND
AT HARBOR FREIGHT OR SIMILAR) BE GENTLE WHEN PRYING AS TO NOT
BREAK THE FACTORY PANEL CLIPS. ONCE YOU GET THE FIRST FEW POPPED
YOU SHOULD BE ABLE TO PULL IT THE REST OF THE WAY WITH YOUR
HANDS.
NOTE- SOMETIMES THE CLIPS WILL GET STUCK IN THE DOOR. ALL
YOU NEED TO DO IS POP THEM OUT AND SLIDE THEM BACK IN TO
THEIR LOCATION ON THE TRIM PANEL.
4. WITH THE DOOR TRIM REMOVED; YOU WILL SEE THE FACTORY VAPOR
BARRIER. YOU WILL WANT TO SLOWLY PEEL BACK THE TOP RIGHT CORNER
BEING CAREFUL TO KEEP THE ADHESIVE ON THE VAPOR BARRIER TO MAKE
RE-INSTALLATION EASIER. PEEL IT BACK ABOUT HALFWAY.
TRIM PANEL
REMOVAL
TOOLS
PEEL THIS
CORNER
FIGURE 4
FIGURE 5

FLATLINE VAN CO • [e-mail] • 888-667-5576 7
5. NOW GRAB YOUR EXTERIOR DRILL TEMPLATE AND LINE IT UP WITH THE
EDGE OF THE DOOR AND EDGE OF SHEET METAL UNDER THE WINDOW (OR
WINDOW SPACE) AND MARK YOUR HOLE TO DRILL.
6. GRAB YOUR DRILL AND START BY DRILLING A HOLE WITH YOUR PILOT BIT,
THEN FINISH THE HOLE WITH THE 27/64” DRILL BIT. WE RECOMMEND
DEBURRING THE HOLE WITH A DEBURRING TOOL OR COUNTERSINK, AND
THEN PAINTING THE EXPOSED EDGES WITH A RUST PREVENTATIVE PAINT.
FIGURE 6
FIGURE 7

FLATLINE VAN CO • [e-mail] • 888-667-5576
7. NEXT WE DRILL THE INSIDE MOUNT HOLE. LINE UP THE INTERIOR DRILL
TEMPLATE AS SHOWN TO THE RIGHT, TAKING CARE TO ALIGN IT WITH THE
EXISTING HOLES IN THE DOOR. THE TEMPLATE IS DESIGNED TO WRAP
AROUND THE SHEET METAL AS SHOWN. THE STRIP SHOULD MAKE FULL
CONTACT WITH THE SHEET METAL OF THE DOOR THROUGHOUT THE WRAP.
8. ONCE MORE, GRAB YOUR DRILL AND START BY DRILLING A HOLE WITH YOUR
PILOT BIT, THEN FINISH THE HOLE WITH THE 27/64” DRILL BIT. WE
RECOMMEND DEBURRING THE HOLE WITH A DEBURRING TOOL OR
COUNTERSINK, AND THEN PAINTING THE EXPOSED EDGES WITH A RUST
PREVENTATIVE PAINT.
8
ALIGN THESE
3 HOLES
FIGURE 8
FIGURE 9

FLATLINE VAN CO • [e-mail] • 888-667-5576
9. NOW IT’S TIME TO GET THE DOOR PLATFORM BOLTED UP. HAVE SOMEONE
HELP YOU BY INSERTING THE HARDWARE AS SHOWN WHILE HOLDING THE
DOOR PLATFORM IN PLACE. LEAVE THE HARDWARE LOOSE FOR NOW.
9
3/8-16 FLANGED
NYLON INSERT
LOCKNUT
3/8-16 X 1 FLANGED
HEX HEAD SCREW
3/8 SCREW BONDED
SEALING WASHER
3/8-16 X 1.5 FLANGED HEX
HEAD SCREW
FIGURE 10
FIGURE 11