Let's Go Aero BIGBOX User manual

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BBOXManual-081717Rev
ASSEMBLY, INSTALLATION, AND OPERATION INSTRUCTIONS:
PRODUCT MANUAL
For More Information & Accessories, Visit our Website - www.LetsGoAero.com
For Technical Support & Product Questions Contact Us at 877-464-2376 or 719- 630-3800
Email: [email protected]
Installation & Safe Use Operation Highlights
Fits 2” size receiver hitches.
Rated for 300 lbs of cargo payload. 160 lbs empty weight.
Class II minimum tow rating required; Class III recommended.
BIGBOX
Slide-Out Enclosed Cargo Carrier System
Set Item Product

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A1 COVER
C2 BULK HEAD
D 4 PIN NUT
E4 SOCKET HEAD SCREW, 1/4-20 x 50 mm.
F2 FLEXIBLE EDGING
H6 PHILLIPS SCREW,10-24 x 1.25
J6 NYLOCK NUT 10-24
L2 CABLE
M2 PULL LATCH, ZINC,
N6 SELF-TAPPING PHILLIPS SCREW .75”
P2 KEEPER PLATE 1.5 x 2
Q2 HINGE
R6 NYLOCK NUT 1/4-20
S4 WASHER, .3” x 1”
T4 HEX HEAD SCREW, 1/4-20 x 1
REQUIRED TOOLS:
5/32” ALLEN WRENCH, RUBBER MALLET, 3/8”
WRENCH, 7/16” WRENCHES, PHILLIPS SCREWDRIVER,
DRILL AND DRILL BITS, HAMMER, CENTER PUNCH,
FELT TIP PEN, ALCOHOL AND CLOTH
A
C
F
X
U4 SELF-TAPPING HEX HEAD SCREW .75”
V2 HEX HEAD SCREW, 1/4-20 x 1.5”
W6 WASHER, .75” O.D.
X4 METAL STRAP
Y2 SPRING
AA 1 FLAT PIPE SPINE
BB 2 SPRING NUT
CC 6 LARGE LOCK WASHER
DD 4 LARGE FLAT WASHER
EE 2 SPRING NUT
FF 2 RETAINER CLIP
GG 1 SILENT HITCH PIN
HH 1 HAND-TIGHTEN SILENT HITCH PIN
JJ 1 PLASTIC WASHER
KK 1 GEARCAGE RACK
D
E
HJ
N
P
U
ST
Y
Q
L
M
R
V
W
PARTS LIST
QTY.DESCRIPTION QTY.DESCRIPTION

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Shank
AA
Compress one Spring Nut [BB] within the FlatPipe Spine [AA] end as shown.
The Spring Nut may be installed between either the rst or the second
mounting hole (user choice) [Figure 1].
NOTE: The FlatPipe Spine [AA] end (called the “Shank”) contains two (2)
mounting holes. The ideal hole for use is the second hole in from the end of
the shank. If the shank bottoms out inside the receiver hitch, or if you need to
maximize clearance, use the rst hole in from
the end [Figure 2].
NOTE: For proper carrier balance, there is a
3° pitch on the FlatPipe Spine [AA]. Be sure
when installing that your FlatPipe Spine is
right side up [Figure 2].
STEP 1
3° Pitch AA
BB
1st Hole
2nd Hole
[Figure 1]
[Figure 2]
Hitch Receiver
[Figure 3]
STEP 2 TOOLS: 7/8” SOCKET WRENCH
Slide the shank end of the FlatPipe Spine [AA] into the receiver hitch aligning the mounting hole with the hole in the
receiver hitch [Figure 3]. Secure the Spine with the Silent Hitch Pin [GG], one (1) Large Lock Washer [CC], and one (1)
Large Flat Washer [DD] by threading the Silent Hitch Pin into the Spring Nut [BB] [Figure 4].
NOTE: The Large Lock Washer [CC] should be located closest to the hex head end of the Silent Hitch Pin [GG]. Tighten
the Silent Hitch Pin until the Lock Washer becomes fully compressed. Attach the Retainer Clip [FF] to the end of the Pin.
AA
Hitch Receiver
BB
BB CC
DD
FF
[Figure 4]
Never operate the vehicle without the Silent Hitch Pin fully secured with a 7/8” wrench. Failure to do so may result
in bodily injury and property damage. Always check to be sure the Silent Hitch Pin is snug before transit.
WARNING:
STEP 4
Insert the remaining Spring Nut [BB] into either open end (user choice) of
the FlatPipe Spine [AA]tubes.
Align the Spring Nut [BB] threading with the hole at the end of the FlatPipe
Spine tube in the same manor as STEP 1 [Figure 8].
NOTE: Placement of the Spring Nut [BB] is left to user discretion. The user
may place the Spring Nut in either side of the Flat Pipe Spine tubes [AA].
AA BB
AA
GG

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STEP 5
STEP 6
STEP 7
Slide the GearCage Rack [KK] all the way back
onto the Flat Pipe Spine [AA].
AA KK
Hitch Receiver
Slide the Large Plastic Washer [JJ] onto the Hand-Tighten Silent Hitch
Pin [HH].
In the same manor as Step 2, insert and thread the Hand-Tighten
Silent Hitch Pin [HH] with the Plastic Washer [JJ] through the Flat Pipe
[AA] and GearCage Rack [KK] and internal Spring Nut [BB]. Secure
with Retainer Clip [FF].
NOTE: The Hand-Tighten Silent Hitch Pin [HH] controls the slide out
function of the GearCage Carrier. Once installation is complete, the
Hand-Tighten Silent Hitch Pin may be removed and the carrier can be
slide rearward for rear hatch/door access.
HH
KK
FF
JJ
From underneath the carrier, connect the quick-link end of the Safety
Cable to the hole in the frame of the Flat Pipe Spine [AA].
NOTE: The Safety Cable can be secured in two (2) positions. Securing
the Safety Cable to the 1st Position is ideal; carriers positioned for
maximum clearance will need to use the 2nd Safety Cable position.
1st Position
2nd Position
Never operate the carrier’s slide out function or the tow vehicle
without conrming the Safety Cable fully secured. Failure to follow
product guidelines may result in bodily injury and property damage.
WARNING:
AA
UNDERNEATH CARRIER VIEW

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NOTE: This step will be easiest if someone
assists you.
Form cover [A] around bulk heads [C]
inserting edges of bulk heads into groove
of cover as you go. Attach at remaining two
corners with pin nuts [D] and at head hex
head screws [E] using the same method
used in STEP 8.
STEP 9 TOOL: 5/32” HEX WRENCH
A
C
C
D
E
STEP 10 TOOL: RUBBER MALLET
Press t (by hand) edging [F] around edge of cover [A]. Hammer edging with mallet for
a tigher t. Repeat for other side. F
A
NOTE: You may also squeeze the edges of the edging [F] all along its length for a
tighter t.
GCAF 1014 0
Insert the bulk head [C] into
the groove near the edge
of the cover [A]. Insert pin
nut [D] making sure the slot
end is towards the outside.
Insert and tighten joint con-
nector bolt [E].
Repeat to attach the remain-
ing bulk head to the other
side of the cover [A].
A
C
STEP 8 TOOL: 5/32” HEX WRENCH
C
D
E
DETAIL 1
C

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the end tube. Repeat for the second keeper
plate. Remove the AerFoil and turn the GearCage
upside down on a stable and level surface. Center punch an
indentation at each pen mark. Drill 1/8” dia. holes. Attach keeper plate
at holes by inserting and tightening three self-tap screws [N]. Repeat for
the second keeper plate. NOTE: Tip of screws [N] are self-drilling. You
may choose to power drive the screws without pre-drilling if you have
the tools and skill to do so.
STEP 11 TOOLS: DRILL AND 3/16” BIT, 1/8” BIT, 3/8” WRENCH, PHILLIPS SCREWDRIVER, HAMMER, CENTER PUNCH
Using existing holes as a guide,
drill through the plastic (use 3/16”
bit). Attach latch [M] as pictured
using two each [H, and J]. Repeat
for attachment of other latch.
Position the keeper plate [P] on
the underside of the GearCage
end tube, aligning it with the latch.
Use a felt-tip pen to mark the three
hole centers on the under side of
B
M
N
P
J
H
DETAIL 4
END TUBE
STEP 12 TOOLS: DRILL; 1/4” & 13/16” BITS, 3/8” & 7/16” WRENCHES, HAMMER, CENTER PUNCH
Using existing holes as a guide, drill through
the plastic (use 3/16” bit). Attach one hinge [Q]
using two each [R,S, T]. Repeat for attachment
of the other hinge.
The bottom of the hinge will attach to the tube
using self-tap screws [U].
Center punch an indentation at each hole cen-
ter. Drill 3/16” dia. holes. Attach hinge at holes
by inserting and tightening two self-tap screws
[U]. Repeat for the other hinge.
NOTE: Tip of screws [U] are self-drilling as well.
You may choose to power drive the screws with-
out pre-drilling if you have the tools and skill to
do so.
TUBE
U
S
T
R
Q
STEP 13 7/16” WRENCHES
Remove existing nut and bolt
from the OUTSIDE, BOTTOM
of the GearCage (DETAIL 8).
Attach one end of the cable [L],
adding washer [W]. Tighten, but
leave some play.
Using existing hole as a guide
(third hole in from the corner),
drill through the plastic with
3/16” bit (DETAIL 9).
Attach other end of cable [L] as
shown using [V, R, W]
Repeat to attach remaining
cable to other side. Tighten all
fasteners securely.
DRILL
THROUGH
PLASTIC
W
V
R
L
NOTE: For this
conguration
cables are installed
to the exterior of
the Aerfoil.
DETAIL 9
DETAIL 8
W
L

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E
REMOVE AND
REATTACH
STEP 10 TOOL: 5/32” HEX WRENCH
DETAIL 10
X
Y
X
NOTE: This step will be easiest if someone assists you.
IMPORTANT: Remove and reattach each bolt ONE AT A TIME before moving on to the next bolt. Removal of more
than one bolt at a time may cause Aerfoil to come apart!
Join two straps [E] together with one spring [Y] at ends with the smallest holes. Repeat for remaining two straps.
Attach strap/spring assemblies by bending around the top edge of Aerfoil as shown. The padded side of the straps
goes against the Aerfoil. Start at one corner where screw [E] must be removed. Thread the screw through the hole
in the end of the strap, then reattach. Repeat for the other side and then for the remaining strap/spring assembly.
IMPORTANT!
WEAR SAFETY GLASSES AND
GLOVES FOR THIS STEP.
!
ONE YEAR LIMITED WARRANTY
We warrant this Let’s Go Aero brand product during the time the original retail purchaser owns it. This warranty terminates if a
purchaser transfers the product to any other person.
Let’s Go Aero warrants this product to be free from defect in material and workmanship for one year (retain your sales receipt for
your records). Any product or part thereof found to be defective within that period will be replaced without charge provided that:
(1) the product was not misused; (2) no alterations or modications were made; (3) its failure was not a result of normal wear
expected in the use of the product; (4) the product or part is delivered, freight prepaid, to Let’s Go Aero.
Manufacturers only obligation shall be to replace such products or parts proved to be defective. A Return Merchandise Authoriza-
tion is required prior to return. Please contact Let’s Go Aero toll-free, at 877-464-2376 or 719-630-3800, or via email to support@
letsgoaero.com to get an RMA number.
No warranty is given for LGA products purchased outside of the United States and Canada.
Technical Support
For assistance with this product, please contact us:
Let’s Go Aero, Inc.
Phone: [phone] or 719-630-3800
Email: [email protected]
To learn more about our products and stay informed about
useful options for transporting all kinds of gear with your
carrier, be sure to visit our website: www.LetsGoAero.com
Copyright© 2017, Lets Go Aero, Inc., All rights reserved.