Zipp Manufacturing I-BOX, Building Instructions

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33
Measuring depth of shaft tube in strut.
Shaft tube with smooth bend.
Shaft tube installed.
Collet type
Slide the strut onto the far end of the shaft tube,
until it stops. Mark the tube, pull the strut off and
measure how far it went in. Write this down.
Bolt the strut on with 2 bolts. Make sure you can
adjust the strut freely.
Set the strut so that its centerline is about ½ inch
below the bottom of the boat, and parallel.
Adjust the shaft tube so that it is aligned with the
strut. You can turn the tube slightly in the stuffing
tube, so that it’s next to the strut.
Make a mark where the front of the strut is, and
remove the tube.
Make another mark back from your first, using the
measurement you wrote down earlier.
Cut the shaft tube here, and file the end smooth.
Remove the strut, slide the shaft tube into the
stuffing tube and slide the strut onto the end of the
shaft tube. It should easily bolt to the transom.
If not, find out why and correct it.
When satisfied with the shaft tube, mark the front
and cut it to the same (distance from the collet) as
the stuffing tube. File any burrs.
Reinstall the strut and shaft tube (again?).
Loosen the collet and slide your assembled flex
shaft in until it bottoms out in the collet. Do this
several times, and make sure it goes in about ¾ of
an inch.
Tighten the collet slightly with two wrenches.
Measure the distance from the back of the strut to
the front of the drive dog. Subtract 1/8 inch from
your measurement.
Remove the cable assembly and cut the cable by
the amount you just determined.
To cut the cable, use a motor tool with a cut off
disk, and file or grind the end smooth.
Put the cable back in, and there should be a 1/8
inch gap between the strut and drive dog.
The actual running gap will be ¼ inch, as we will
pull the cable back 1/8, to keep it from bottoming
out in the collet.
You must have this ¼ gap when running, as the
cable will “wrap up” and get shorter in use.