slide it back to access the wiring connections.

Once the rear cover is removed, the wiring process is the same on both connectors.

PLASTIC NUT

REAR WIRING
COVER

COMPRESSION
CAP

REAR WIRING
COVER

LOCKING TAB
CONNECTOR
BASE

Figure 23k

Figure 23h
FURRION CONNECTOR

EPICORD CONNECTOR
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 29

7. Slide the rear housing off the back of the recptical (Figure 23m) to expose the wire connections.
8. Use a hand held screw driver with the appropriate bit (flat head, Phillips head or #2 square drive) to
loosen the four (4) screws holding the wires in position on the back of the receptical (Figure 23n).
REAR HOUSING

Figure 23m

Figure 23n

9. Pull the wiring out of the back of the receptical (Figure 23p). Cap the wires and insert them back through
the hole in the sidewall. Set receptical and all associated parts aside for later reinstallation (Figure 23s).

Figure 23p

Figure23s

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 30

10. Using a screw gun and a #2 square drive bit, remove the skirting along the lower side wall of the unit up to
the kitchen slide-out (Figure 24). Some prying may be required to remove the skirting.
11. Peel back the edge of the rubber roofing that hangs over the edge of the side wall (Figure 25). Use a plastic
prying device (like a Polystick) that will not puncture or otherwise damage the roofing material.

Figure 24

Figure 25

12. Use a template and grease pencil to mark the cut line for the fiberglass above the kitchen slide-out (Figure
26a and 26b).

30”

32”

6”
Figure 26a

TEMPLATE
TEMPLATE

Figure 26b

NOTE: Sample measurements are approximate, but
work with most floor plans.

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 31

+ NOTICE
In the following steps, cut ONLY the fiberglass sidewall. DO NOT cut structure or supports as this may lead to
structural damage. There are metal structural components, and sometimes wiring in this area. Cutting deeper
than the fiberglass risks damaging anything behind it.

13. Once the fiberglass is marked, use a pneumatic saw to cut the fiberglass along the curved mark (Figure 27a
and 27b). NOTE: Cut ONLY the fiberglass - DO NOT cut any structure or support.

Figure 27a

Figure 27b

14. Using prying tools, separate the fiberglass exterior from the aluminum structure (Figure 28a, 28b, 28c, and
28d). Safely pry and pull the exterior fiberglass off of the aluminum frame structure as necessary.

Figure 28a

Figure 28b

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 32

Figure 28c

Figure 28d

15. The fiberglass is backed with an azdel material which may separate from the fiberglass and stick to the
structure. Once all of the fiberglass has been removed, use a putty knife, oscillating multi-tool or a grinder,
remove ALL of the azdel and any residual adhesive from the aluminum wall structure (Figure29a and 29b).

AZDEL

AZDEL

Figure 29a

OSCILLATING
MULTI-TOOL

Figure 29b

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 33

SIDEWALL STRUCTURE MODIFICATIONS

CAUTION
CAUTION: WEAR PROTECTIVE EQUIPMENT while welding. Burn injury from weld spatter, and blindness can
occur from looking at the weld in progress without proper protective equipment. NEVER stare into or look
directly at the sparks and weld without a welding mask that protects eyes and skin. Wear a protective sleeve
to cover clothing and skin. Failure to head these guidelines can result in serious injury, blindness, or death!

CAUTION
CAUTION: Install a cover on the slide-out opening into the bedroom, as well as the openings for the storage
doors. Remove anything flamamable or explosive from the storage compartments, and cover those as well
during the welding process. This protects these areas from damage weld spatter while the sidewall structure
is being modified. Failure to do so may cause potential damage or fire to these areas, resulting in property
damage and possible personal injury.

+ NOTICE

NOTICE: All structural modifications performed in this document use aluminum 3” x 1.5” tubes (see below BRV P/N 100617 for reference). These are cut to size and shape according to the structural prints at the back of
the document, and welded into the sidewall structure (Figure 30).
In corners where there are existing braces, add an additional stacked brace (3” x 1.5”) on top of the existing
brace (Figure 31).

3” X 1.5” TUBES

ADD BRACE

ORIGINAL
BRACE

Figure 30

Figure 31

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 34

+ NOTICE

NOTICE: It is IMPORTANT to place the pinbox of the RV in a tripod or stand before begining structural
modifications (Figure 32). This simulates towing to align and stress the structure as it would see when
traveling. The tripod (or stand) is only required during sidewall structure modifications.

1. Mark the sidewall structure for additional bracing. Starting at
the edge of the kitchen slide-out, measure as indicated on the
attached prints and mark the foam insulation for installation of
braces. Vertical braces (when added) are typically installed on 48”
centers. NOTE: On the prints RED means ADD this reinforcement,
YELLOW means ADD IF NOT ALREADY THERE (Figure 33 - this
photo is an example of the structural modifications - actual prints
are attached to the end of this document).

Figure 32

Figure 33

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 35

2. Using a magic marker pen (or equivelant) and a 2” x 6” aluminum brace tubes to lay out the modificatons to
the sidewall (Figure 34).
3. Once the vertical, horizontal and diagonal structure bracing marks are layed out on the sidewall structure,
use a razor knife to cut along the lines, then use a 6” putty knife to chisel the styrofoam out for installation of
the braces (Figure 35a and 33b).

Figure 34

Figure 35a

4. Cut the Styrofoam out of each corner and joint where the original structure was built. Inspect for broken
welds (Figure 36a and 36b). Inspect ALL original welds on the exposed sidewall and mark for repair as
needed.
INSPECT
WELDS

Figure 35b

Figure 36a

BROKEN
WELD

Figure 36b
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 36

5. Cut the braces to size for each opening and test fit (Figure 37).
6. Install the bracing in the sidewall using Chem X adhesive (P/N 100650) (Figure 38).

Figure 37

Figure 38

7. Tape the braces in place if necessary to hold them while the Chem X sets - typically overnight (Figure 39).
8. Cover any openings and finished surfaces to prevent weld spatter from causing damage (Figures 40a and
40b).

SPATTER
COVER

Figure 39

Figure 40a

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 37

9. Prepare the structure for welding by installing a bolt on the sidewall structure for the welder (Figure 41).
Attach the lead from the welder to this point.

SPATTER
COVER

Figure 40b

Figure 41

10. When the braces are all in position, begin welding them to the sidewall structure (Figure 42a, 42b, 42c, and
42d). Repair any original welds that were broken at this time as well.

Figure 42a

Figure 42b
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 38

Figure 42c

Figure 42d

11. When all the welds are complete, inspect them thoroughly for gaps and holes that may have occurred during
the process (Figure 43).
12. When satisfied of the quality of the welds, use a power grinder and a T-29 aluminum disc (BRV P/N 111955
for reference) to grind the welds flush (Figure 44a and 44b).

WELDS

Figure 44a

Figure 43

Figure 44b
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 39

13. Once all of the welds have been ground flush,
give each weld a final inspection for gaps, holes
or breaks (Figure 45- sample - all welds should be
flush like this example).

WELDS FLUSH
NO GAPS OR
HOLES

14. Use expanding foam to fill the gaps and voids
in the styrofoam insulation that were created to
inspect the original welds (Figure 46).

Figure 45

SPRAY
FOAM

Figure 46
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 40

15. Use CHEM X (P/N 100650) or similar adhesive to install EGS (Electro Galvanized Steel) backer panel
covering the stryofoam above the slide-out (Figure 47a and 47b). Tuck the right end behind the existing
fiberglass at the curved cut above the slide-out, and press it flat into the opening. Also install EGS along the
curved edge of the front structure where the front cap will attach (Figure 47c).
EGS BACKER

EGS BACKER

Figure 47a
EGS BACKER

Figure 47b

FRONT CAP
CURVE

Figure 47c

16. Once all holes are filled, use a power grinder and a T-29 aluminum disc (BRV P/N 111955 for reference) to
scuff all of the aluminum surfaces where they will contact adhesives to improve adhesion (Figure 48a and
48b).

Figure 48a

Figure 48b

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 41

FIBERGLASS WALL INSTALLATION
1. With the new sidewall layed flat, use the original template used 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 fine tooth blade to cut the straight opening for the slide-out (Figure 49).

Figure 49

2. Use a saber saw with a fine tooth blade to
cut the curved section that goes over the
kitchen slide-out (Figure 50).

Figure 50
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 42

3. Thoroughly clean the mating surfaces of the aluminum sidewall structure using Alodine (P/N 101444) and
clean shop rags or microfiber towels (process 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” boards to the sidewall area 104” (measured from the top of the roof edge) to rest
the sidewall on when installing it (Figure 51). These are TEMPORARY supports for the sidewall during
installation.

SIDEWALL
SUPPORT
2” X 4”

SIDEWALL
SUPPORT
2” X 4”

Figure 51

5. Lift the sidewall into position to test fit (Figure 52a). If the shop does not have a hoist, at least 4 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 52b).

TEST FIT

CURV

E CUT

Figure 52a

Figure 52b
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 43

+ 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 53a, 53b, 53c, and
53d, and 53e on page 44 and 45).

Figure 53a

Figure 53b

Figure 53c

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 44

Figure 53d

Figure 53e

8. Be certain adhesive is applied to all mating surfaces for maximum contact and adhesion (Figure 54).

Figure 54

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 45

+ 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 55). 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 one of the panels to the contour of the
front cap opening (as seen in Figure 61b, page 50),
To press the wall firmly for the extended curing period (24 hours), have eight (8)
1/4”X2”X2” angle, in 12’ lengths ready (Figure 62a, page 50). Additional pressure is
applied to the sidewall while the adhesive is curing by inserting shims between the
angle pieces and the plywood panels (Figure 64a and 64b, page 51).
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 55

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 56).

Figure 56
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 46

2. Once the sidewall is positioned properly, press the sidewall firmly against the adhesive on the sidewall
structure (Figure 57 and Figure 58).

SLID

E an

d PR

ESS

Figure 57

Ma
tch
C

urv
es

Figure 58

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 47

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 59a,
59b and 59d), and the bottom of the fiberglass to the wall structure (Figure 59c and 59e). 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