10. Prepare the structure for welding by installing a bolt on the sidewall structure for the welder (Figure 93b).
Attach the lead from the welder to this point.

WELD
BLANKET

Figure 92b

Figure 93a

11. When the braces are all in position, begin welding them to the existing sidewall structure (Figure 94a, 94b,
and 94c). Repair any original welds that were broken at this time as well.

Figure 93b

Figure 94a
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Figure 94b

Figure 94c

12. When all the welds are complete, inspect them thoroughly for gaps and holes that may have occurred during
the process (Figure 95).
13. When satisfied with the quality of the welds, use a power grinder and a T-29 aluminum grinding disc (not
supplied) to grind the welds flush (Figure 96a and 96b).

Figure 96a

Figure 95

Figure 96b
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14. Once all of the welds have been ground flush,
inspect each weld for gaps, holes, or breaks (Figure
97 - sample - all welds should be flush like this
example).
15. Use expanding foam (not supplied) to fill the gaps
and voids in the styrofoam insulation that were
created to inspect the original welds (Figure 98).

Figure 97

SPRAY
FOAM

Figure 98
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16. Use CHEM X (P/N 100650) or similar adhesive to install EGS (Electro Galvanized Steel) backer panel
covering the stryofoam above the through-frame slide-out (Figure 99a and 99b). Tuck the right end behind
the existing fiberglass at the curved cut, and press it flat into the opening.
EGS BACKER

EGS BACKER

Figure 99a

Figure 99b

17. Once all holes are filled, use a power grinder and a T-29 aluminum disc (P/N 111955) to scuff all of the
aluminum surfaces where they will contact adhesives to improve adhesion (Figure 100a and 100b).

Figure 100a

Figure 100b

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FIBERGLASS WALL INSTALLATION
1. With the new sidewall layed flat, use the original template to mark the cuts for the slide-out opening, and the
curved end at the top that mates to the existing sidewall over the kitchen slide- out. Use a circular saw with a
sharp blade to cut the straight opening for the slide-out (Figure 101).

Figure 101

2. Use a jig saw with a sharp blade to cut the
curved section that goes over the kitchen
slide-out (Figure 102).

Figure 102
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3. Thoroughly clean the mating surfaces of the aluminum sidewall structure using Alodine (P/N 101444) and
clean shop rags or microfiber towels (not shown). Allow to thoroughly dry before applying adhesives. Rotate
or replace wiping clothes regularly during the cleaning process.
4. Screw two (2) 2”X4”x 24” boards to the sidewall area 104” from the top of the roof edge to rest the sidewall
on when installing it (Figure 103). These are TEMPORARY supports for the sidewall during installation.

SIDEWALL
SUPPORT
2” X 4”

SIDEWALL
SUPPORT
2” X 4”

Figure 103

5. Lift the sidewall into position to test fit (Figure 104a). If the shop does not have a hoist, a minimum of 5
technicians are required. Place it on the 2”X4” support rests, and make sure it covers everything, and the cut
curved joint above the kitchen slide-out mates properly to the curved cut in the existing wall (Figure 104b).

TEST FIT

CURV

E CUT

Figure 104a

Figure 104b
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+ NOTICE
The adhesive being used - ECO-TITE hybrid adhesive (P/N 117553) - has a “Skin Over” flexible set up

time of 30 minutes on initial application, and a curing time of 24 hours. Refer to the manufacturer’s
instructions for safety and clean-up procedures. The sidewall needs to be in position and being
secured within 30 minutes of application of adhesive.
Adhesive should be applied liberally, but not excessively. Eleven (11) tubes of ECO-TITE typically
provides sufficient coverage for twenty (20) linear feet of wall section. Windows, slide-outs, storage
doors and appliance openings may be different from one floorplan to another, but in most applications
11 tubes per 20 linear feet of wall provides strong adhesion.
BE CERTAIN THE ADHESIVE IS APPLIED TO ALL METAL AND STYROFOAM SURFACES AS SHOWN.
6. Once the test fit is confirmed, pull the sidewall
fiberglass down and set carefully aside (not shown).
7. Using a pneumatic gun, apply ECO-TITE hybrid
adhesive sealant (P/N 117553) on ALL aluminum
structure AND Styrofoam surfaces that will contact
the new exterior wall (Figure 105a, 105b, 105c, and
105d, 105e, and 106 on page 43).

Figure 105a

Figure 105b

Figure 105c

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Figure 105d

Figure 105e

8. Be certain adhesive is applied to all mating surfaces for maximum contact and adhesion (Figure 106).

Figure 106

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+ NOTICE
NOTICE: The adhesive used to hold the fiberglass to the sidewall structure is PRESSURE ACTIVATED, and
must have the proper pressure applied to adhere to and cure on both surfaces. The following instructions
outline the procedure to apply sufficient pressure to activate the adhesive.
Prepare six (6) 4’X8’ Sheets of 3/4” finished plywood by covering one side in felt
(Figure 107). These will be used to secure the wall at the top and bottom for curing. For
easier installation at the front of the unit, trim the panels to the contour of the front cap
opening (as seen in Figure 113b, page 48),
To press the wall firmly for the extended curing period (24 hours), have eight (8)
1/4”X2”X2” angles, in 12’ lengths ready (Figure 114a, page 48). Additional pressure is
applied to the sidewall while the adhesive is curing by inserting shims between the
angle pieces and the plywood panels (Figure 116a and 116b, page 49).
To expedite the final steps of the fiberglass installation, prepare these items in
advance, and have them ready before applying the adhesive to the sidewall structure.

FIBERGLASS WALL INSTALLATION

FELT COVERED
PLYWOOD

Figure 107

1. Lift the sidewall into position and rest on top of the 2”X4” supports. slide the wall into position on these
supports BEFORE pressing the fiberglass back onto the adhesive (Figure 108).

Figure 108

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2. Once the sidewall is positioned properly, press the sidewall firmly against the adhesive on the wall structure
(Figure 109 and Figure 110).

SLID

E an

d PR

ESS

Figure 109

Ma
tch
C

urv
es

Figure 110

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3. Using a screw gun with a #2 square drive bit, begin attaching the fiberglass sidewall to the roof structure
using 2-1/2” wood screws (P/N 100904) - fasten the top of the fiberglass to the wooden roof sill (Figure
111a, 111b and 111d), and the bottom of the fiberglass to the wall structure (Figure 111c and 111e). Continue
to apply pressure to the fiberglass as it is being attached to the body structure (not shown).
FIBERGLASS
SIDEWALL
ROOF SILL
2-1/2” WOOD SCREW
P/N 100904

Figure 111a
ALUMINUM
SIDEWALL
STRUCTURE

Figure 111d
SIDEWALL/ROOF CROSS SECTION

Figure 111b
FASTEN BELOW FLOOR LINE

FIBERGLASS
SIDEWALL
ALUMINUM
SIDEWALL
STRUCTURE

FLOOR

Figure 111c

2-1/2” WOOD SCREW
P/N 100904

Figure 111e
SIDEWALL/FLOOR CROSS SECTION
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4. Once the new fiberglass is secure around the perimeter of the wall structure, use a hand held power saw or
router to begin routing or cutting off the overlap areas (front cap area, baggage doors, etc.) (Figures 112a,
and 112b), Route out the slide-out opening and any window openings in the fiberglass (Figure 112c).

Figure 112a

Figure 112b

Figure 112c

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+ NOTICE
NOTICE: It is often easier to hang the plywood covers if they are cut for the front angled section of the
sidewall where the front cap attaches, as well as where the storage compartment doors are located.
5. Using a screw gun and #2 square drive bit, install the felt covered plywood panels over the fiberglass using
2-1/2” wood screws (P/N 100904) (Figures 113a and 113b). Secure them at the top into the roof sill, and at
the bottom into the exposed structure BELOW the sidewall.

Figure 113a

Figure 113b

6. Use a screw gun with a #2 square drive bit to secure the L-brackets over the plywood panels using 3” #10
wood screws (P/N 104187) (Figure 114a). Use two (2) L-brackets back-to-back to secure the panels as
shown (Figure 114a). Secure at the top and bottom.
7. Use clamps to secure the openings for the slide-out, basement doors, and the front cap area (Figures 114b
and Page 50, Figure 117). Where possible, place clamps at a minumum of 12” apart, closer where applicable.
TWO (2)
L-BRACKETS

Figure 114a

Figure 114b

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8.

L-BRACKET

PIN BOX

RATCHET
STRAP

Figure 115
9. Secure the forward most L-brackets at the bottom with a ratchet
strap to the pin box (Figure 115).

SHIM

10. Insert shims between the L-brackets and plywood panels to
provide additional pressure on the sidewall to further activate
the adhesive (Figure 116a, and 116b).

Figure 116a

Figure 116b

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+ NOTICE
The cure time for the supplied adhesive is 24 hours. DO NOT remove bracing until cure time has passed.
DOUBLED
L-BRACKETS

FIBERGLASS INSTALLED,
CLAMPED, BRACED AND
SHIMMED FOR CURING
(FIGURE 117)

DOUBLED
L-BRACKETS

CLAMPS
CLAMPS

Figure 117
REASSEMBLY AND PREP FOR PAINT
1. Once the adhesive has had sufficient
time to cure, remove all of the
L-brackets and plywood bracing
from the side of the RV (not
shown).

RE

LIE

FC

UT

Figure 117a

Figure 117b

2. Using a hand held mini-saw, make a vertical relief cut
at the front lower corner of the slide-out opening. Cut
3/16” deep to ensure ONLY the skin and backer are cut
(full material depth is approximately 0.250” or 6.35mm)
DO NOT cut into the metal sidewall structure under the
skin. (Figure 117a and 117b).

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REASSEMBLY AND PREP FOR PAINT (CONT’D)
3. In preparation for fiberglass work and final application of paint and graphics, the following steps need to
be performed. Refer to the prior removal instructions if there are questions about fit, measurements or
fasteners.
•

Installation of the front cap - connect all wiring, then tuck the roof membrane along the back edge and
sides of the cap prior to securing the cap in place. Install trim and seals prior to paint.

•

The roof membrane can be rolled over onto the sidewall, but should not be secured. DO NOT install the
roof rail at this time. The roof rail must be loose for paint and fiberglass work, and is to be installed after
the unit is painted.

•

Installation of the bedroom slide-out - all interior and exterior components of the bedroom slide-out
should be installed, adjusted, and working properly when the unit goes to paint. The room should operate
as normal, traveling completely in and out when sent to paint.

•

Installation of cargo and appliance doors - these should be secure, adjusted for proper operation and
locking, sealed, and ready for paint prior to sending to the paint shop.

4. Perform body and paint work. Repair any defects in fiberglass, screw holes, and sealant prior to painting.
5. Install graphics as necessary.
6. Final inspection, leak test and detailed review of body work, paint and exterior sealants.
7. lnstallation complete. File claim through Brinkley Dealer Portal or through Brinkley Customer Care
Department at [email protected].

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WI-014-2025 Sidewall Replacement Rev-D
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RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

G3500 STRUCTURE COLOR KEY

G3500 WALL
STRUCTURE

X

ADD STRUCTURE

WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

X

ADD STRUCTURE

G3250 / G3950 / G4000 STRUCTURE COLOR KEY

G3250/G3950 / G4000
WALL STRUCTURE

WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
Page 54

RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

Z3610 STRUCTURE COLOR KEY

Z3610 WALL STRUCTURE

X

ADD STRUCTURE

ADDITIONAL VENDOR INFORMATION ACCESS
Additional information is available on various systems and components you may encounter while performing
the repairs in this document. The QR codes listed below provide links to the various manufacturer’s service
and/or installation information. If there is a discrepancy between the instructions provided by Brinkley in
this document and the component manufacturers information, default to the component manufacturers
instructions.
If you have additional questions, please contact Brinkley Customer Care at 888-502-3460, or 574-501-4280,
Mon-Fri, 8AM to 5 PM EST, or email: “[email protected]”.
Lippert Slim-Rack Slide-Out
Progamming, Installation and
Service Manual

Installation and
Service Instructions

KORAPUR urethane adhesive
sealant (Brinkley P/N 112154)
Adhesive Information

General
Information

Safety Data Sheet

EternaBond MicroSealant
Tape (Brinkley P/N 102489)

Information

Installation
Instructions

Safety Data Sheet

WI-014-2025 Sidewall Replacement Rev-D
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