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| Chapter 3: Assembly Instructions
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Assembly Instructions
Refer to Assembly Illustration (Figure 1) on Page 3
Before installation, consider which side on your cart you
want to install the front door panel and which side you want
to install the rear panel. Due to access and reach, you will
install the back panel first, the side panels next, and the front
door panel last. When installing panels, lay the resin cart on
protective material, such as cardboard.
Step 1: Installing Back Panel
1. Choose the side of the cart where you want the front
door panel installed and lay that side down on protective
material. The side of the cart you want the back panel
installed should be facing up.
2. Lay the panel in place on the cart. Make sure the panel
is centered side to side within the opening. Push the
panel to the top of the cart opening.
3. There should be equal gaps between the panel and the
cart at the top, left to right, and at the bottom, left to
right. If the panel fit does not result in equal gaps, plan
to square the cart to fit the panel as much as possible. If
attempting to square the cart, during step 4 below, drill
and install one top corner carriage bolt first. Apply pres-
sure to the cart to create equal gaps and drill and install
the second carriage bolt diagonally across to the lower
corner on the opposite side. Drill and install remaining
carriage bolts as instructed in step 4 below.
4. With the panel in place, use a 7/32” drill bit and match-
drill the six carriage bolt locations along the panel sides.
Take care to drill the center of the bolt location and don’t
allow the drill bit to slide to the side before biting into
the cart material. Make sure to drill all the way through
to the cart material.
5. Insert six M5 x 20mm carriage bolts through the panel
and cart. Attach the carriage bolts using six 5mm wash-
ers and six 5mm external-tooth lock nuts. Tighten nuts
firmly using 8mm socket. NOTE: Press each carriage bolt
neck into the slot/hole and against the panel. Use pres-
sure, a weight, or temporary tape to keep the carriage
bolts in place while installing the washers and nuts.
Step 2: Installing Side Panels
1. Turn the cart 90-degrees on protective material to ex-
pose one of the side panel locations.
2. Repeat steps 2 through 5 under “Installing Back Panel”
to install the first side panel.
3. Turn the cart 180-degrees on protective material so the
opposite side panel location is facing up.
4. Repeat steps 2 through 5 under “Installing Back Panel”
to install the final side panel.
Step 3: Installing Front Door Panel
1. Lay the back panel side of the cart down on protective
material. The side of the cart for the front door panel
should be facing up.
2. Lay the front door panel in place on the cart as shown
in Figure 1. Cut the zip tie to release the latch. Rotate
the latch to allow the front door panel to rest flat against
the cart. Make sure the panel is centered side to side
within the opening. Push the panel to the top of the cart
opening.
3. With the panel in place, use a 7/32” drill bit and match-
drill the ten carriage bolt locations along the panel sides,
upper strut, and lower strut. Take care to drill the center
of the bolt location and don’t allow the drill bit to slide to
the side before biting into the cart material. Make sure to
drill all the way through the cart material.
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