Koenders Superior Windmill, Assembly Manual

Page: 5 / 13

5
FRAME SETUP INSTRUCTIONS
IMPORTANT NOTE: Do not tighten any bolts until tower is fully assembled.
The setup of this tower will go much quicker and more organized if you do some pre-assembly.
The entire cross bar supports can be bolted together as per Figure 1. Also, the multi-strut
systems can be bolted together. The section you opt to end at finishes with the ground stake
clamps (item 4). These will be bolted to the last two holes of the bottom legs used. See Figure 3
next page for more details.
NOW TO BEGIN ASSEMBLY...
A)
Begin the tower at the very top. Take all three top portion tower legs (ITEM S1) and fasten
them to the plastic tower top (ITEM 1) with twenty-four 5/16” self-tapping screws (ITEM 3).
Tighten all of these screws. DO NOT OVER TIGHTEN AS THESE SCREWS CAN STRIP IN
PLASTIC.
Note: These screws are all you should tighten until the tower is complete.
B)
After these legs are fastened, install the top portion struts (ITEMS S21, and S22). These are
to be mounted with the flat side of step against the inside of the tower leg.
C)
Hold the next set of 48” tower legs (ITEM S2) to the back of the first set of legs. You also
have to hold up a 23” brace (ITEM S31) to the back of the legs and run a 1/4” x 3/4” bolt
through the top hole of all three items. (Don’t put the bolt through the bottom hole yet as the
cross bar supports will have to be added.)
D)
After all three 23” struts are in place put a bolt through the top hole of the 19” support bars
(ITEM S42) and bolt it to the bottom hole of the top tower leg (ITEM S1).
E)
The next step involves assembling several parts at the same time. You have to run a bolt
through a 33 3/4” cross bar support (ITEM S45), the top hole of the second and third level of
48” legs, and finally the 41” strut (ITEM S33). On the other side of the leg instead of the 33
3/4" cross bar supports you need to bolt in the cross bar tensioner (ITEM 2) and the 29 1/2"
cross bar (ITEM S44).
Note: Make sure that only one cross bar tensioner ends up in each corner.
Note: Make sure that 5/16” x 1/2” inch nuts and bolts are used to secure center of all cross
bar supports.
F)
The next cross bar assembly consists of two 27 1/4" cross bars (ITEM S43), one 38 1/2”
cross bar (ITEM S47), one 33 3/4" cross bar (ITEM S45), and a cross bar tensioner (ITEM 2).
Bolt the two 27 1/4" pieces to the bottom holes of the second level legs. Bolt the 38 1/2" piece
and the 33 3/4" with the tensioner to the top hole at the bottom of the third level legs. You
stop at the 12’ section bolt on the two 32” struts (ITEM S32) between each leg. Bolt on the
ground stake clamps and you’re done. If you’re building the 20’ assembly please read on.
G)
Before you bolt on the 32” struts, add another 48” leg in between them and the third level leg.
A 35 1/4" cross bar support (ITEM S46) will also have to be added to the outside of these
holes.
H)
Repeat steps A-F to complete the 20’ assembly using Figure 1 to find correct part placement.
I)
Tighten all nuts and bolts.