Havis-Shields KK-K9-D22-K User manual

KK-K9-D22-K_INST_9-07
INSTALLATION INSTRUCTIONS KK-K9-D22-K
K-9 TRANSPORTATION KIT
2005-2008 DODGE MAGNUM
TOOLS REQUIRED:
Power Drill
Drill Bit Set
Standard Wrench Set
Standard & Metric Socket Set
Ratcheting Wrench
Screwdriver Set (Cordless powered)
Wire cutters
Wire Strippers
Crimping tool
Caulking gun
HARDWARE:
QTY: DESCRIPTION: USED FOR: PART #:
8 #10 x ¾” Stainless flat head screw Door Panel (top lip) GSM34151
32 #10 x ¾” Stainless sheet metal screw Door Panel GSM34170
40 #10 x ½” Stainless sheet metal screw Fillers/Step sill GSM34169
8 #10 x ½” Stainless flat head screw Window guard hinge GSM34150
29 ¼-20 x ½” Stainless carriage bolt Basic unit assembly GSM32022
44 ¼-20 Serrated nut Basic unit assembly GSM30023
7 ¼-20 x ¾” Stainless carriage bolt Lexan filler GSM32024
8 ¼-20 x ¾” Hex head bolt Front cage bracket GSM33001
4 ¼” x ¾” Hex head lag bolt Front cage bracket GSM33060-1
1 Tube silver silicone Sealant PRM97343
3 #10 x ¾ Sheet metal screw Dome light GSM33195
COMPONENTS:
QTY: DESCRIPTION:
1 Front Cage
1 Rear Cage
1 Floor
1 Ceiling
2 Front Cage Upper Lexan Fillers
2 Front Cage Lower Aluminum Fillers
2 Step Sill Aluminum Fillers
2 Rear Cage Lower Aluminum Fillers
2 Rear Cage Upper Aluminum Fillers
2 Aluminum Ceiling Fillers
2 (2-pc) Front Cage Brackets
2 Aluminum Door Panels
2 Hinging Window Guards w/brackets
1 Dome Light Kit
1 Rubber Mat
1 Rear-Mounting Foot

KK-K9-D22-K_INST_9-07
# Description
1. Front Cage
2. Rear Cage
3. Floor
4. Ceiling
5. D.S Front Cage. Upper Lexan Filler
6. P.S. Front Cage Upper Lexan Filler
7. D.S. Front Cage Lower Aluminum Filler
8. P.S. Front Cage Lower Aluminum Filler
9. D.S. Step Sill Aluminum Filler
10. P.S. Step Sill Aluminum Fillers
11. D.S. Rear Cage Lower Aluminum Filler
12. P.S. Rear Cage Lower Aluminum Filler
13. D.S. Rear Cage Upper Aluminum Filler
14. P.S. Rear Cage Upper Aluminum Filler
15. D.S. Ceiling Filler
16. P.S. Ceiling Filler
17. D.S (2-pc). Front Cage Bracket
18. P.S. (2-pc) Front Cage Bracket
19. Rubber Mat (Not shown)
20. Rear-Mounting Foot
D.S. = Driver Side
P.S. = Passenger Side
Item # 2
Item # 11
It
em # 17
Item # 5
Item # 13
Item # 12
Item # 18
Item # 10
Item # 7
Item # 6
Item # 15
Item # 20
Item # 16
Item # 14
Item # 9
Item # 1
Item # 4
Item # 3
Item # 8
EXPLODED VIEW OF DODGE MAGNUM
K-9 TRANSPORTATION KIT

KK-K9-D22-K_INST_9-07
# Description
1. Front Cage
2. Rear Cage
3. Floor
4. Ceiling
5. D.S Front Cage. Upper Lexan Filler
6. P.S. Front Cage Upper Lexan Filler
7. D.S. Front Cage Lower Aluminum Filler
8. P.S. Front Cage Lower Aluminum Filler
9. D.S. Step Sill Aluminum Filler
10. P.S. Step Sill Aluminum Fillers
11. D.S. Rear Cage Lower Aluminum Filler
12. P.S. Rear Cage Lower Aluminum Filler
13. D.S. Rear Cage Upper Aluminum Filler
14. P.S. Rear Cage Upper Aluminum Filler
15. D.S. Ceiling Filler
16. P.S. Ceiling Filler
17. D.S (2-pc). Front Cage Bracket
18. P.S. (2-pc) Front Cage Bracket
19. Rubber Mat (not shown)
20. Rear-Mounting Foot
D.S. = Driver Side
P.S. = Passenger Side
Item # 6
Item # 18
Item #
16
Item # 17
Item # 1
ASSEMBLED VIEW OF DODGE
MAGMUM K-9 TRANSPORTATION KIT
Item # 15
Item # 14
Item # 11
Item # 9
Item # 7
Item # 5
Item # 13
Item # 2
Item # 4
Item # 3

KK-K9-D22-K_INST_9-07
Always!
 Read all instructions before installing any Havis-Shields Equipment Corp products.
 Check for obstructions (Wire, brake lines, fuel tank, etc.) before drilling any holes!
 Use hardware provided with install kit
TIPS FOR INSTALLATION:
• Cordless drill with Phillips screw bit is recommended to help speed up installation time.
• Rear and ceiling fillers as well as step sill may require you to apply pressure when attaching
them to the cage. This will aid in achieving a clean tight fit and may require two installers during
these steps.
• PVC protective covering should be removed during installation. Peeling it back while attaching
hardware.
SUB ASSEMBLIES:
1. Remove necessary interior trim parts:
• Remove rear seat
• Remove OEM door panels.
Note: if the door has an electric lock system and/or
window controls, the switches must be reconnected.
The switch assembly must be wire tied to inner door
panel and placed inside a plastic bag so, as not to
interfere with the window or lock mechanisms.
• Remove OEM door lock pin assembly
• Remove OEM step sill panel
• Remove seat belts – remove inboard belt latch and buckle (center of car)
2. Loosely attach rear-mounting foot to vehicle using factory seat hardware on floor of vehicle.
Note: DO NOT tighten these bolts until Step 6 of the installation process.
INSTALLATION:
1. Place Floor:
Remove OEM
door rod
Rear of vehicle

KK-K9-D22-K_INST_9-07
• Place floor in vehicle and butt up to rear-mounting foot.
2. Mount Rear Cage:
• Place rear cage on top of floor.
• Attach rear-mounting foot to aluminum floor and rear cage using ¼-20 x ¾” Stainless
carriage bolts and serrated nuts.
• Attach aluminum floor to rear cage using ¼-20 x ½” Stainless carriage bolts and serrated
nuts.
3. Mount Front Cage:
• Place the cage on top of floor.
• Attach bottom of cage to floor using ¼-20 x ½” Stainless carriage bolts and ¼-20 serrated
nuts.
4. Mount Ceiling:
• Place ceiling on top of front and rear cages being careful not to rip headliner.
• Attach using ¼-20 x ½” Stainless carriage bolts and serrated nuts.
Aluminum
Floor
Rear Cage
Rear-mounting foot
Front Cage
Ceiling

KK-K9-D22-K_INST_9-07
5. Mount Aluminum Step sills
• Center floor inside vehicle.
• Front edge of floor will line up with front edge of step sill. Top of Step sill will mold to curve
of trim.
• Pre-drill and attach using #10 x ½” Stainless sheet metal screws.
6. Front and Rear Mounting Brackets.
• Lower “B” pillar trim will need to be partially removed
to allow for mounting to metal behind trim.
• Loosely attach 2-pcs front mounting brackets to front
cage using ¼-20 x ¾” carriage bolts and serrated nuts.
• Mark and pre-drill where mounting bracket comes into
contact with “B” pillar support.
• Attach to metal “B” pillar support using ¼” x ¾” Hex
head lag bolts.
• Trim will have to be notch to accept bracket.
• Tighten all hardware on front and rear cage mounting
brackets.
Step Sill
Front Cage Mounting Brackets

KK-K9-D22-K_INST_9-07
7. Rear Lower Fillers
• Position and attach to rear cage using #10 x ¾” Stainless sheet metal screws.
• Filler lines up with bend on rear cage,
• Attach to step trim using #10 x ¾” Stainless sheet metal screws.
Note: apply pressure to filler panels while installing, in order to get a clean tight fit.
8. Rear Upper Fillers:
• Applying pressure to rear upper filler panel, tight to rear cage ceiling and
bottom trim, mark and pre-drill mounting holes
• Attach to cage using #10 x ¾” Stainless sheet metal screws.
9. Ceiling Fillers
• Position ceiling filler to fill gap between ceiling of K-9 unit and vehicles headliner.
• Mark, pre-drill and attach using #10 x ½” Stainless sheet metal screws.
Rear Lower filler
Rear Upper
Filler
Ceiling filler

KK-K9-D22-K_INST_9-07
10. Mount door panels:
• Center so edges do not hang over.
• Attach top lip of door panel to vehicles door
using #10 x ¾” Stainless flat head screws. Be
sure to use a 5/32” pilot and wax screw.
• Proceed to mount remainder of door panel.
• Starting at the top and working your way
down, pre-drill w/ 5/32” drill bit and attach to
door using #10 x ¾” Stainless sheet metal
screws.
Note: Starting at the top and working your way
down will insure a clean tight fit to the door.
Note: apply wax to screws to avoid screw head from snapping.
Final Door Panel
Installation
N
ote: Product is painted black for Demo purposes only. Product is shipped unpainted
Door Panel
Installation

KK-K9-D22-K_INST_9-07
11. Mount window guards:
Note: window guards have holes around perimeter for
permanent mounting. These holes are not used with hinge kit.
They also come flat in shipping. The guard must be pre-bent
(outward) so it fits the contour of the vehicles window frame.
Do not use holes on side of window guard to mount with the
hinge application!
• Hold window guard with pre-assembled hinge and upper
bracket onto window frame.
• Make sure guard is centered on window.
• Hinge window down being sure to keep window guard centered and mark holes using
window guard as template on 1” bent lip of door panel.
• Pre-drill and attach hinge to lip on door panel using #10 x ½” Stainless flat head sheet metal
screws.
• Hinge window guard back to up position with upper mounting bracket attached and mark
mounting holes.
• Pre-drill and attach upper mounting bracket to window frame using #10 x ½” Sheet metal
screws.
• Re-attach window guard to bracket. This step may require some adjustment to align thumb
screws to nut-certs on bracket.
Note: Product is painted black for Demo purposes only. Product is shipped unpainted
Contour Window Guards

KK-K9-D22-K_INST_9-07
13. Front Lower Aluminum Fillers:
• Attach as shown using (3) ¼-20 x ¾” carriage
bolts and serrated nuts.
• Close door to position, then tighten.
14. Front Upper Lexan Fillers:
• Close door to position.
• Drill ¼” holes through lexan and cage.
• Attach using (3) ¼-20 x ¾” carriage bolts and
serrated nuts.
• Tighten all hardware.
15. Silicone:
• All gaps and seams must be sealed.
16. Rubber matting:
• After silicone is dry, place rubber matting.
17. Dome Light Switch Box:
• The switch box location can be at the
customer’s discretion.
• Mounting on driver’s side of the vehicle in
upper left corner is recommended.
Final Hinging Widow
Guard Installation
N
ote: Product is painted black for Demo purposes only. Product is shipped unpainted
Switch Box
Front Filler
panel
installation