Let's Go Aero HexCap User manual

HexCap Hardshell Tonneau Cover
Tonneau Cover For LittleGiant & SPEC Ops Trailers
P/N T00482
PARTS LIST
Qty Description
Body Cover
Front Bulk Head (With Hinges)
Rear Bulk Head (With Handle)
Flush End Gate Screws
Standard Pin Nuts
HexCap Insert
Bracketed Ball Stud & Assemblies
Ball Stud Bracket Spacers
Ball Studs & Assemblies
Hinge Tek Screws (SM)
Gas Lifts
Latch Plates
Weather Stripping
Weather Stripping Tex Screws (LG)
Cover Bands
Band Springs
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
1
1
1
4
4
1
2
2
2
4
2
2
2
4
4
2
Step 1:
TOOLS REQUIRED:
M6 Hex Key
5/32in Hex Key
3/16in Hex Key
Starting with one End Gate
corner of the trailer only. Remove
the existing Black End Cap from
one corner of the Trailer End
Gates. Save this End Cap for
later replacement.
Loosen the existing corner bolt
and remove it. This bolt can be
discarded.
Remove the existing Metric Pin
Nut. This Pin Nut can also be discarded.
[Figure 1 & 2]
5/16in Hex Driver
13mm Wrench
1/2in Wrench
7/16in Wrench
3/8in Wrench Driver
5/16in Drill Bit
TOOL REQUIRED: 13mm or 1/2in Wrench
Drill
Phillips Screw Driver
A
D
L
Q
K
P
G
N
H
M
JER
B
C
F
EXISTING
BOLT
EXISTING
PIN NUT
EXISTING
END CAP
Page 1 of 7
[Figure 1]
[Figure 2]
HEXCAP MANUAL 081419

Step 2:
Step 3:
Step 4:
Insert one (1) Standard Pin Nut [E]
where the existing Metric Pin Nut was
removed in Step 1.
Using one (1) Flush End Gate Screw [D],
insert the screw into the interior of the
tube where the existing bolt from Step
1 was removed passing through the Pin
Nut. [Figure 3]
NOTE: The Flush End Gate Screw [D]
should be placed into the INTERIOR of
the tube so that head of the bolt rests
INSIDE the tube.
Re-install the Black End Cap that was removed from Step 1. [Figure 4]
Repeat Steps 1 & 2 for the remaining THREE corners of the Trailer End Gates.
Remove the pre-installed Joint Connector Bolts
from each side of the Front & Rear Bulk Head [B
& C] and set the bolts aside. [Figure 5]
NOTE: Do not remove the pre-installed Pin Nuts.
IMPORTANT - THIS STEP REQUIRES TWO PEOPLE FOR
PROPER INSTALLATION.
Place the HexCap Body Cover [A] on a large at surface.
Starting at one end of the Body Cover, align both Bulk Heads [B
& C] into the grooves inside the cover.
NOTE: The Rear Bulk Head (with Handles) [C] MUST be
installed on the side of the Cover with the pre-installed Latch
Keepers. Be sure the hardware (handles and hinges) on BOTH
Bulk heads faces away from the HexCap Body Cover.
Install two (2) Joint Connector Bolts removed from Step 3 into
the holes at each corner of the Hexcap Cover [A] securing the
Pin Nuts in both Bulk Heads to the Cover as shown. [Figure 6]
TOOL REQUIRED: M6 or 1/4in Hex Key
TOOL REQUIRED: 5/32in Hex Key
TOOL REQUIRED: 5/32in Hex Key
D
D
E
EXISTING
END CAP
B
B
C
C
JOINT
CONNECTOR BOLT
JOINT
CONNECTOR BOLT LATCH
KEEPER
A
Page 2 of 7
[Figure 3]
[Figure 4]
[Figure 5]
[Figure 6]

Step 5:
Step 6:
Step 7:
IMPORTANT - THIS STEP REQUIRES TWO PEOPLE FOR PROPER INSTALLATION.
Tightly roll both Bulk Heads [B & C] into the grooves of the HexCap Body Cover [A]. [Figure 7]
Install the remaining two (2) Joint Connectors Bolts through the corners of the HexCap Body to secure the Bulk Heads to
the cover. [Figure 8]
NOTE: Be sure the Joint Connector Bolts on each end are properly threaded through each pre-installed Pin Nut.
Flex and place the HexCap Insert [F] into the center of the HexCap Cover
Assembly by causing tension between the metal siding of the Assembly as
shown. [Figure 9]
IMPORTANT - THIS STEP REQUIRES TWO PEOPLE FOR PROPER INSTALLATION.
Place the HexCap Cover Assembly SQUARELY on the trailer with the
Front Bulk Head (with Hinges) [B] onto the front of the trailer as shown.
[Figure 10]
Using the Hinges as a guide, mark the holes for the Hinges. Using a
drill, drive the Hinge Tek Screw (SM) [K]
into the trailer to attach the Cover Assembly
to the Trailer. [Figure 11]
Fully secure the pre-installed Upper Hinge
Bolts to the Cover using a 7/16in Wrench.
TOOL REQUIRED: 5/32in Hex Key
TOOL REQUIRED: Drill; 5/16in Hex Driver; 7/16in Wrench
A
A
A
A
B
K
K
F
B
B
B
C C
JOINT
CONNECTOR BOLT
UPPER
BOLTS
Page 3 of 7
[Figure 7] [Figure 8]
[Figure 9]
[Figure 10]
[Figure 11]

Step 8:
Step 9:
IMPORTANT - THIS STEP REQUIRES TWO PEOPLE FOR PROPER INSTALLATION.
Lift and hold open the HexCap Cover open. Locate the pair of holes on each side of the HexCap Cover. Using the
Screws and Washers included on the Bracketed Ball Stud [G], insert the Button-Head Bolts and one (1) washer through
the outside of the trailer. [Figure 12 & 13]
On the inside of the trailer, secure the Bracketed Ball Stud [G] to the trailer using the Ball Stud Spacer [H] and the
remaining Washers and Nuts from the Bracket Ball Stud Assembly as shown. [Figure 14]
Repeat this process for the other side of the trailer.
NOTE: This connection is a tight t.
IMPORTANT - THIS STEP REQUIRES TWO PEOPLE FOR PROPER INSTALLATION.
From the front of the trailer locate the #5 U-Tube. Measure 1in across and 1in down and mark this spot. Drill a hole using
a dill with a 5/16in drill bit in the marked location. [Figure 15 & 16]
On the inside of the trailer, insert one (1) Ball Stud [J] with two (2) of the attached Washers into the newly made hole.
On the outside of the trailer, secure the Ball Stud with the remaining Washers and the included Nut as shown.
[Figure 17]
Repeat this process for the other side of the Trailer.
12345678
Top of Trailer
#5 U-Tube
1in
1in
TOOL REQUIRED: Drill; 5/16in Hex Driver; 1/2in Wrench
TOOL REQUIRED: 3/8in Wrench; Philips Head Screw Driver
BRACKETED BALL
STUD ASSEMBLY
BRACKETED BALL
STUD ASSEMBLY
BRACKETED BALL
STUD ASSEMBLY
BRACKETED BALL
STUD ASSEMBLY
G
H
BALL STUD
ASSEMBLY
BALL STUD
ASSEMBLY
J
Page 4 of 7
[Figure 12]
[Figure 15]
[Figure 16]
[Figure 17]
[Figure 13]
[Figure 14]

IMPORTANT - THIS STEP REQUIRES TWO PEOPLE
FOR PROPER INSTALLATION.
Lift and hold open the HexCap Cover Assembly open.
Snap the Gas Lifts [L] onto the Ball Stud Assemblies
[J] and Bracketed Ball Stud Assemblies as shown [G].
[Figure 18]
TIP: If ever necessary, for safe removal of the Gas Lifts
[L] from the Ball Studs
[G & J] use a Flat Head
Screw Driver to loosen the
plastic “Clip” on each Gas
Lift end before removing
from the Gas Lift from the
Ball Studs. [Figure 19]
Step 10:
Step 11:
Locate the End Gate Brackets on the rear of the Trailer below the pre-installed Latch Keepers.
Working with one End Gate Bracket at a time, Remove the two (2) bolts holding the End Gate Bracket in place. [Figure
20] Place the Latch Plate [M] over the End Gate Bracket and align the holes.
Secure the Latch Plate [M] and End Gate Bracket to the Trailer by re-installed End Gate Bracket Bolts just removed.
[Figure 21]
Repeat this Step for the other side of the Trailer.
TOOL REQUIRED: 1/2in Wrench
END GATE
BRACKETS
EXISTING
BOLTS
EXISTING
BOLTS
G
J
L
M
PLASTIC
“CLIP”
Page 5 of 7
[Figure 18]
[Figure 20] [Figure 21]
[Figure 19]

Step 12:
Step 13:
Step 14:
Apply Weather Striping [N] to each end of the HexCap Body Cover [A]. [Figure 22]
Secure the Weather Stripping [N] to the Cover [A] by driving the Weather Stripping Tex Screws (LG) [P] through the
Weather Stripping and into the Cover. [Figure 23]
Connect two (2) Cover Bands [Q] together using the supplied Cover Band Spring [R].
[Figure 24]
Repeat this Step with the remaining Cover Bands [E] and Spring [R] creating two
complete Cover Band Assemblies.
Make sure the Latches are engaged and in the locked position.
Working with only one (1) Joint connector bolt at a time. Remove one (1) Joint Connector Bolt from ends of each
Bulk Head [B & C] and then re-install the Joint Connector Bolt securing one end of the Cover Band Assembly [Q & R] to
the edge of the Cover. [Figure 25 & 26]. Repeat this Step for the remaining three corners of the HexCap Cover to fully
secure each Cover Band.
NOTE: The Cover Band should overlay the Weather Stripping [N] by approximately 1/4in.
TOOL REQUIRED: 5/32in Hex Key
TOOL REQUIRED: Drill; Philips Head Driver
NP
QQ
Q
R
R
N
N
A
JOINT
CONNECTOR BOLT JOINT
CONNECTOR BOLT
Page 6 of 7
[Figure 22]
[Figure 24]
[Figure 25] [Figure 26]
[Figure 23]

ONE YEAR LIMITED WARRANTY
We warrant this Let’s Go Aero brand product during the time the original retail purchaser owns
the product. 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 Authorization (RMA) 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 [email protected] to
get an RMA number.
No warranty is given for LGA products purchased outside of the United States and Canada.
To register your product, visit the Let’s Go Aero website at www.LetsGoAero.com
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
Patent and trademark protected.
Patent Numbers 6,609,725; 6,945,550; 8,079,613; D717718; 8,858,141; Patents Pending
Copyright© 2017, Lets Go Aero, Inc., All rights reserved.
Technical Support
For assistance with this product, please contact us:
Let’s Go Aero, Inc.
4474 Barnes Road
USA
Phone: [phone] or 719-630-3800
Email: [email protected]
ALWAYS BE SURE THE LATCHES ARE FULLY LOCKED AND SECURE BEFORE TRANSIT. FAILURE TO
PROPERLY LOCK AND SECURE THE HEXCAP LATCHES MAY RESULT BODILY INJURY, DEATH, AND/OR
PROPERTY DAMAGE. NEVER BEGIN TRANSIT WITH THE HEXCAP COVER LATCHES UNLOCKED
ALWAYS BE SURE ALL CONNECTIONS ARE SNUG AND FULLY SECURE BEFORE TRANSIT. FAILURE TO
PROPERLY CONNECT AND SECURE ALL CONNECTIONS MAY RESULT BODILY INJURY, DEATH, AND/OR
PROPERTY DAMAGE.
WARNING
WARNING
Page 7 of 7