REAR RAMP DOOR 2.0 REPLACEMENT EXTRUSIONS

Purpose

This document outlines the procedures to replace two side extrusions or side and top extrusions on the rear
ramp door. If more than two extrusions need to be replaced or if the bottom or hinge side extrusion is to be
replaced, contact LCI. Procedure is only applicable to ramp doors with corner keys and external fasteners.

Safety

The "CAUTION" symbol above is a sign that a procedure has a safety risk involved that may cause
personal injury and/or product damage, including voiding of warranty, if not performed safely and
in accordance with the safety procedures stated herein.

Moving parts can pinch, crush or cut. Keep clear and use caution.

Resources Required

« Replacement extrusions, - 342" T-handle ¢ White gunnable glue
maximum of two * Rubber mallet ¢ Glue gun
¢ Cordless or electric drill or + Five-way tool ¢ Caulk
screw gun « Putty knife ¢ Caulk gun
¢ Appropriate drive bits ¢ Screw extractor « Clamps
Procedure

1. Use T-handle to loosen screws on the corner keys of the damaged extrusions to be replaced (Fig. 1).

2. Remove the screws from each end of the extrusions being replaced.

Rev: 03.25.20 CCD-0003471

REAR RAMP DOOR 2.0 REPLACEMENT EXTRUSIONS

On the interior side of the door, slide a five-way tool under the extrusion channels and tap with a
rubber mallet every 4" along the channel to loosen the extrusion from the core (Fig. 2).

4. If the tool and tapping procedure doesn't break the extrusion free, turn the door over and repeat the
procedure on the exterior side of the door.

NOTE: Take care not to scratch the fiberglass.

5. After removing the damaged extrusion, use the five-way tool to remove remaining glue from the
interior side of the core.

6. Usea putty knife to remove remaining glue from the exterior side of the core.
7. Apply white glue end to end on both sides of the inside lip on the extrusion channels without leaving
voids. The glue must be located only on the inside of the channel flanges (Fig. 3) and not in the corners.

No Glue He

Channel Flanges

Rev: 03.25.20 CCD-0003471

REAR RAMP DOOR 2.0 REPLACEMENT EXTRUSIONS

Place corner keys into the ends of extrusions (Fig. 4) and then install the extrusion on the edge of the
core. Seat extrusion with a rubber mallet. Corners must line up.

Door Core

Vertical Extrusion

_/,
exam,

Corner Key

Horizontal

Extrusion i 1

9. Make sure corner keys are fully seated into the ends of the corresponding extrusions.
10. Clamp the corners and install screws through the extrusions (Fig. 5). The screws must be installed flush
with the extrusions.

Screws

11. Using a caulk gun, reapply caulk on the seams on both sides of the door.

As a supplier of components to the RV industry, safety, education and customer satisfaction are our primary concerns. Should you
have any questions, please do not hesitate to contact us at (574) 537-8900 or by email at [email protected]. Self-help tips,
technical documents, product videos and a training class schedule are available at Ici1.com or by downloading the MyLCl app.

Rev: 03.25.20 Page 3 CCD-0003471