HOLDEN VU-VZ SERIES2 LID FIT
FLEXIGLASS FITTING MANUAL - SECTION 2.2B
HOLDEN COMMODORE VU-VZ SERIES 2 LID FIT - ISSB2
Note: Familiarise yourself with the instructions before you start to ensure you are clear on all aspects of the fit
SAFETY EQUIPMENT MATERIALS & PARTS REQUIRED ● Hearing protection as required Part No. Description Qty. ● Eye protection as required - Ute Lid 1 BLTCHSS620 Bolt M6X20 S/S Cuphead 4 TOOLS REQUIRED PLT190 Handle Latch Plate 2 ● Pneumatic / electric drill STRUT100 Gas Strut 430X300N 2 ● Pneumatic / electric hacksaw BKT150C Door Bracket Black Coat 2 ● Pneumatic / hand rivet gun BAR130C VU Hinge Support Bar Coat 1 BKT180C VU Hinge Corner Fillet Brckt C 1 BKT190C VU Hinge Corner Fillet Brckt C 1 HIN180 VU Bottom Hinge 2 PLT140 Catch Plate 2 NUT6N Nut Nyloc M6 4 RIVET220 Rivet 5MM Steel 6-12 24 SCRHHTX1625 Screw Hex 10-16X25 Zp S/Drill 8 SEAL650 FOAM STRIP 200MM 1 SEAL235 Drip Seal 1.7 SEAL325 Seal D Rubber 0.3 SEAL460 Seal VU hinge LH 1 SEAL475 Seal VU hinge LH 1
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● Due to the design of the rear cabin bulkhead of the VU Commodore Ute. A water shedding flange has had to be designed to eradicate water leakage as far as is possible.
1 Take the hinge support bar BAR130C and the two corner fillet pieces BKT180 (L) & BKT190 (R) and apply TAPE180 to the mounting faces. One strip only is applied to the long BAR130C with the top edge lined up with the bottom of the bend radius. 2 The fillets will require 3 pieces to cover the whole face. See Photo 2.
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HOLDEN VU-VZ SERIES2 LID FIT
2 To make fitting the combined support bar and water shedding flange as easy as possible. Take one 3 corner fillet and position it in its respective corner. A short (approx 50mm long) piece of front angle should be placed over the top angle of the bulkhead as a spacer. See Photo 3.
3 The rear corner of the fillet piece is positioned so that the flat part lines up with the bottom of the coaming inside corner radius, leaving the end of the upturned lip showing above the coaming top. See Photo 4. The BKT180 fillet piece should be approximately 5 mm below the top of the tub. 4
4 With the fillet in place, drill through the holes provided with a ø5 drill bit and fix using RIVET200 rivets.
● Note: It was found while experimenting with the VU ute that the alloy side coaming and the front bulkhead are both very thin. If tek or self tapping screws were used it was very easy to strip the hole. Hence the decision to use rivets.
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5 Take the BAR130C bar and fit it into the gap between the bulkhead and the stepped end of BKT180. This is best done by rotating the rear lip of the centre bar upwards inserting the 90° bend into the gap then rotating it down flat again. Lightly clamp. See Photo 5.
6 Insert the other BKT180 unit into position against the vehicle and under the main bar, clamp this end lightly. The clamped assembly will not fall out of its position. See Photo 6. 6 7 Hold the fillet piece up into place and drill and rivet the first hole in the main bar. This will compress the foam tape and pull the fillet forward to its correct position.
8 The fillet can now be riveted to the side of the tub in the same manner and position as the first unit.
9 Drill and rivet the remaining main bar front holes.
10 Drill 5mm holes down through the overlap of the fillet pieces using the main bar holes as guides.
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HOLDEN VU-VZ SERIES2 LID FIT
11 Remove clamps, squeeze sealant into the joint between the fillets and main bars. Ensure the rivet 7 holes have sealant around them then rivet the joints with RIVET200 rivets.
12 Sealant should now be squeezed into the joint starting at the rear of the fillet forward along the coaming then across the bulk head and back to the rear of the opposite fillet piece be generous but neat with this bead.
13 From underneath the fillet pieces apply a bead of sealant from each end of the main support bar into the coaming tonneau cover recess be sure to squeeze plenty into this corner. See Photo 7
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14 Apply some TAPE180 3mm truck tape to the underside of the two HIN180 VU bottom hinges. See Photo 8.
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15 Using 2 of BLTCHSS620 stainless cap head bolts and Nyloc nuts per hinge, bolt the hinges into place through the slotted holes provided. See Photo 9. Do not fully tighten at this stage they should remain moveable from side to side by hand.
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16 Fit the SEAL460 & SEAL460 L&R foam pads into position. See Photo 10.
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HOLDEN VU-VZ SERIES2 LID FIT
17 Take the length of SEAL235 “J” drip seal and fit it to the rear lip of the mount support bar assembly. At the ends continue it onto the coaming and trim the 11 J drip seal to match the end of the SEAL460 pad. See Photo 11.
18 At the junction of the fillet pieces to the main support bar there will be found to be a small gap this should be filled with sealant.
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19 The BKT150C ball joint brackets can be fitted to the inside of the coaming now. Measure 880mm from the rear of the bulkhead. See Photo 12.
20 The first bend of the ball joint plate is then slid up to the edge of the coaming top rib and riveted into place. See Photo 13.
21 Using a Torx T40 driver, remove the rear-most 8mm coaming screw See Photo 14.
22 Fit the catch plate PLT140 to the coaming using the 8mm screw previously removed. Set the catch plate lip 25 - 30mm below the coaming top and 13 tighten finger tight.
23 The lid can now be fitted by lifting the rear end until about 45° is reached and the top hinges engaged into the slots on the lower hinges.
24 Carefully check the fit of the lid on the tub with the tail gate closed. The “squeeze up” of the bulb should be as even as possible. The kink in the bulb seal at the font corners is inevitable which is why the inner seal on the support bar continues over the coaming top.
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HOLDEN VU-VZ SERIES2 LID FIT
25 When the fit is good. Carefully lift the lid sufficiently 14 to open the tail gate. Lower the lid and check it hasn’t moved out of position.
26 Climb into the tub with the lid closed and tighten the upper hinge screws (2 per hinge) and the lower hinge bolts.
27 Remove the lid and turn it upside down. Lock the top hinges into place by fixing the remaining 8 x SCRHHTX1616 button head screws per hinge through the holes provided.
28 Fit and adjust the latch bar position on the handle shaft. 15 - 20 mm should be set between the body of the handle and the top of the latch bar lock nut. See Diagram 15.
29 Now that the bottom hinge position is fixed, run some sealant around the two sides and rear edge of each hinge. Pay special attention to the area of the slotted holes as they may become exposed during final adjustment and will allow water to drain into the tub.
30 Re fit lid, attach gas struts making sure the cylinder is upper most when in the open position. 15 31 Close the lid with the tail gate open and adjust the “pull down” on the handles by moving the PLT190 catch plates up or down. Check closure is tight but not over tight with tail gate closed. Tighten 8mm screw fully.
32 Drill through 2 or more of the 4 holes provided in the 16 catch plate. Fit RIVET200 rivets and pull them up to lock the plate permanently in place.
33 Clean the rectangular area on the rear passenger side corner of the lid with IPA and attach the XDE022 nationwide sticker.
34 Clean and check lid ready for delivery.
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