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27. Prepare the material for TIG process welding.
28. Because of a lack of clearance when welding
under the reinforcement tubing, make the back
cap of the welding handle shorter as shown in
Figure 18. Use a rubber cap and black tape to
close the back cap. If available, use specific
equipment according to your TIG torch.

FIGURE 17

FIGURE 18

29. Prepare twelve aluminum ER 5356 filler rods
with a diameter of 3/32’’.

FIGURE 19

30. Install an extra 5-pound fire extinguisher ready
to use, inside the vehicle. Do not use fire
extinguishers supplied with the vehicle.

FIGURE 20

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31. Cover the whole slide-out wooden floor with a
fire retardant blanket.

FIGURE 21

32. Fit and install sheet metal parts behind all the
future welding areas to protect the external
panel of the slide-out from overheating.

FIGURE 22

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33. Prepare a garden hose with a gun to supply
fresh water for the cooling of the slide-out wall
from the outside when welding.

CAUTION
Slide-out external panel may curve if
overheated. Make sure to always keep the
temperature of the external panel down.
Keep spraying fresh water on the external wall
of the slide-out for all welding steps.

FIGURE 23

CAUTION
When welding, touch the external panel with
a hand to check the temperature. If the
temperature increases ask the welder to
stop welding a while and keep spraying
fresh water.

CAUTION
Apply the disconnection procedure shown
at the beginning of this instruction sheet
prior welding.

FIGURE 24

34. Install the reinforcement tubing on the structure
with the 135 mm high spacer blocks at both
ends. Make sure the 135 mm high spacer
blocks stand on the aluminum slide-out
structure and not on the wooden floor.
35. Install a 163.4 mm high spacer block under the
reinforcement tubing in the middle.

CAUTION
Open the entrance door, roof hatches and
all windows of the vehicle prior to start
welding.
FIGURE 25

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36. Prepare to tack weld the reinforcement tubing.
37. Before tacking, push the reinforcement tubing
to ensure a good contact with the existing
structure.

FIGURE 26

38. Tack weld the top of the reinforcement tubing
with a diagonal existing tubing as shown in
Figure 27.

FIGURE 27

39. Repeat previous steps with all the existing side
poles and all diagonal tubes.

FIGURE 28

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40. Start spraying fresh water on the slide-out
external wall, both sides.

FIGURE 29

41. Follow the typical specification in Figure 30 for
all welding.

FIGURE 30

42. On the left-hand side of the slide-out, weld two
corners at the top of the reinforcement tubing
and one corner at the bottom (Figure 31).
43. Stop welding and keep spraying fresh water on
the outside at least 2 minutes after the welding
has stopped.

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FIGURE 31

44. On the right-hand side of the slide-out, weld
two corners at the top of the reinforcement
tubing and one corner at the bottom (Figure
32Figure 31).
45. Stop welding and keep spraying fresh water on
the outside at least 2 minutes after the welding
has stopped.

FIGURE 32

46. On a first diagonal tubing, weld three corners at
the top of the reinforcement tubing and one
corner at the bottom (Figure 33Figure 31).
47. Stop welding and keep spraying fresh water on
the outside at least 2 minutes after the welding
has stopped.
48. Repeat step 46 and step 47 for all diagonal
tubings.

FIGURE 33

49. Make sure that all gaps are completely filled
when welding.

FIGURE 34

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50. Install all pieces of insulation panels (24) on
side walls and center wall.
51. Use aluminum tape to keep the panels in
place.

FIGURE 35

52. On both side walls of the slide-out, apply red
glue #684196 as shown in Figure 36
53. Apply glue with a small painting roll .

FIGURE 36

54. On center lower wall of the slide-out, apply red
glue #684196 as shown in Figure 37.

IMPORTANT NOTE
Do not apply glue on the vertical face of the
reinforcement tubing. This surface is a
mounting face. Apply glue only on the top and
on the bottom of the reinforcement tubing.

FIGURE 37

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55. Remove 1000 mm long of the membrane sticky
side protection.

FIGURE 38

56. Install the membrane on the right-hand side
wall.
57. Make sure the top of the membrane is flush
with the existing structure.

FIGURE 39

58. Cut to fit.

FIGURE 40

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59. With a professional cutter, remove the excess
length of the membrane at the bottom of the
wall. A clean corner is necessary at the bottom
to apply a sealant.

FIGURE 41

60. Apply 25 mm wide of red glue on the side wall
membrane section as shown in Figure 42. The
center wall new membrane section overlaps 25
mm on both side wall membrane sections.

FIGURE 42

61. Repeat steps 55 to 60 for the left-hand side
wall.

FIGURE 43

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62. Install the membrane on the center lower wall
of the slide-out. Align the top of the center
membrane section with the top of the side wall
membrane section.

FIGURE 44

63. Cut the membrane as shown in Figure 45 to
clear the whole vertical mounting face of the
reinforcement tubing. Make the cutting 10 mm
lower than the top of the reinforcement tubing
and 10 mm higher the bottom.

FIGURE 45

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64. Stick the extra length of the membrane with the
top and the bottom of the reinforcement tubing.

FIGURE 46

65. Rub the whole membrane with a wooden block
to ensure a good contact of the membrane with
the glue.

FIGURE 47

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66. Apply a bead of 25 mm wide of sealant
#685126 at the bottom of all membrane
sections (3).

FIGURE 48

67. Install the rail with the Belleville washers (22)
and the socket head screws (22).
68. Torque the screws to a value of 96 lb-ft.
69. Installation is complete for this position.

Allow 6 hours of labor for this position.

FIGURE 49

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

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