VersaCap

Owners Manual

Table of Contents

Overview 2

Parts List 3

Layout 4

Installation Instructions 5

Using and maintaining your VersaCap 7

1. Combination wrenches
2. 3/8" Socket set
3. Hex key set
4. Power drill
5. 1/8" to 3/8" Drill bits
6. Pliers and cutters
7. Level
8. Measuring tape

1. Read these instructions over carefully before you begin your installation.
2. Be sure you have the correct kit for your model of truck.
3. Lay out and identify all of the parts in your hardware packages. The parts list includes all parts, some of which have already been used in the partial assembly of your covers.

   Note: There may be some variations between your parts and what is shown, since this manual is standard for all sizes of the VersaCap.

4. The VersaCap is unique because of its ability to adjust and fit on many vehicles, including trucks with a tapered box. This means you may be able to reuse the cap when you trade your vehicle in.

1. The first thing to do is to mark the location of the four posts. (Fig. 2) Some masking tape on the bed rail will simplify this procedure. The following measurements are outlined on page 4. Starting from behind the cab, measure the setback "E", then the span "D", also measure the setback "C" at the back of the truck. Also check and match the overall length "A" at the tailgate to be sure the Versacap seal will rest in the correct position. Double check these measurements and move them all back or forward if necessary. Doing this will ensure that the cover is centered over the opening in the truck box. Repeat for the other side.Exception: Vehicle models that require our bed extension must measure the setback starting at the tailgate and measure forward onto the extension. To install the extension, drill and fasten using the two self-tapping bolts provided. (Fig.7)
2. Next, assemble all four support posts.(Fig.2) Clamp the post flush with the top of the bed rail in the correct location. This is done using the clamp provided along with two 3/8 X 1" bolts. Over the rail bedliners interfere in these locations and will require you to cut out a square in order to insert the clamp in under the bedrail. If your vehicle has a stake hole or any other interference that does not allow you to use the clamp, simply use a vicegrip or other fastening device to temporarily hold the top portion of the post in place. (Fig.2)
3. Now level the top portion of these posts and drill a hole down through the bed of your truck.

   Caution: Be sure to check under your vehicle before drilling. Do not drill into any lines, wires or gas tank.

   Fasten the post using the 3/8 X 2" carriage bolts. The bedliner spacer is used to raise this bracket off of the ridges of your bedliner. If your truck does not have a bedliner use the bracket underneath the bed as a spacer over the welded seam.(Fig.2)

4. Attach the support bars using the ½ x 2 ½" cotterless clevis pins. The smaller tube (1 ¼" Dia.) should attach on the drivers’ side and the larger tube (1 1/2" Dia.) on the passenger side. This is not a must but it will make the assembly to the upright position easier. (Fig.4)
5. Lie the rain channel down the center, across the support bars. Install a

   U-bolt on either side once you have located the center. Use the shims provided if you find it necessary to raise the rain channel in order to allow for proper tailgate operation. Once this is accomplished, tighten the U-bolts into place. (Fig.3 & 4)

6. Now attach the covers to the posts. They must be placed onto the truck and aligned with the posts in each corner. Look at the alignment and determine which holes should be used on the posts. If your truck has a tapered bed, you can locate the holes on the front posts differently than at the back posts. Leave all pivots tied to the bottom of the cover until you are ready to attach them. Four adjustment plates (Item 8) are provided for the posts and should be used if you intend to use the two innermost mounting holes for the cover pivots. (Fig.3)

   Note: Carefully prop the cover open or have someone hold it while you insert the 3/8 X 2 " bolts through the correct holes to fasten the pivots onto the posts. Be sure to insert the 3/8" flat washers and some grease into the post on either side of the pivots.

7. Install the gas springs for the cover. Note: Cylinder side of the spring should always be placed toward the cover. You will need to lift the cover to the first open position in order to attach the springs in their extended state. The locking pins provided must be installed to keep the connectors in place. (Fig.3)
8. Now install the lock down latch. Be sure the cover and long pivot is properly seated onto the rainchannel at this point. Take the latch and adjust it to approximately the center of its travel. Hang the latch into the slot that should be accessible from the main span. Mark the holes in the support bar, and drill 9/64" holes to accommodate the #8 x ½" self tapping screws. Repeat for all four latches. (Fig.4)
9. Adjust the main rotary latches on the lid. (Fig.5) The cover should rest on the bedrail with only a small compression of the seal (not flattened).
10. Attach the ball studs to the post position in one of the four holes provided, matching the position chosen for the pivot is recommended. Leave the studs loose until you have installed the gas spring. (Fig.4) Install the remaining four gas springs. You will need to open the cap completely in order to do this.

    Note: Open the cap slowly and carefully, be sure the channel does not contact the outside of your truck box. This can happen if the width adjusting bolts or the adjustment plates are not in the correct position.

    The locking pins provided must be used to keep the connectors in place. (Fig.3)

11. Remove the rainchannel and move the support bars up to the racking position. The width adjusting bolts will need to be adjusted now in order for the locking cotterless pin to fit into the hole provided. Adjusting the setscrews out will bring the covers closer together and allow you to insert the locking pin. Make this adjustment evenly and tight on all four corners. This adjustment will take some time, but it will make the entire unit rigid in the upright position. (Fig.4)
12. The final installation of the 3/8" X 1" Hex bolt is to ensure that the structure will not slip out of place when in use. Be sure that everything is working and located properly. Drill two 3/8" holes through the top slots of the post and into the return of the bedrail to accommodate this bolt. If the location of the post on your particular vehicle is such that you cannot attach a nut onto the hex bolt, use the alternate 3/8" tapping screw provided. Drill only a ¼" hole if you are using the tapping screw. Repeat for each post. (Fig.2 & 4)
13. The optional tailgate lock is fastened into the back corner of your tailgate and onto the rear post of the box. This is done using the #12 x ½" self tapping screws. Once installed you simply drop one of the cotterless pins into the lock whenever you wish to lock the box. (Fig.4)
14. Install the clear protective tape around the box rail to protect the painted surface of the truck.

1. When changing from the flat mode into the cargo position, simply open one cover at a time and release the four lock down latches. Now pull on the cover handles to bring it into the upright position.
2. From either side or the rear of your truck, move the rain channel to its storage location on either side of the truck. (Fig 4)
3. When driving with the cap in the open position, you should always have at least one of the support bars in the upper racking position. This can be accomplished from inside the truck bed or from the side of your truck with the covers in the open position.

   Note: You must always insert the pin into the locking position whenever the support bar is in the racking location.

4. Use some grease on all moving parts to maintain the caps smooth operation.
5. In cold climates be sure the rain channel between the two covers is free of any snow or ice.
6. Caution: Be sure to keep your hands clear of all moving parts when operating the cap. Do not allow children or pets inside the cap. Pinch points on the cap, latches and tailgate can cause serious injuries if used improperly.
7. Do not exceed the Maximum carrying Capacity of 500 lbs. on the upper cargo rack. It is very important to secure these loads properly since they can shift or slide off easily.