NHTSA ID Number: 11034186
Manufacturer Communication Number: WI-011-2025 REV G
TSB/Document Date: 2026-07-01
Summary
Revision G for Model I Front Metal Replacement Instructions. If there is damage to the front metal of a Brinkley Model I travel trailer, this document will provide the needed parts and procedures for the replacement of the front metal, and if necessary, the windshield.
Figure 2
7. Cut wiring for LED light strips (Figure 3A) at the gelcap connectors (Figure 3B) under the front
corners.
8. Using your hands, peel the LED strips (Figure 4A) from the corner trim (Figure 4B) and discard.
C
B
A
B
A
Figure 3
Figure 4
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 6 of 25
9. Using a screw gun and a #2 square drive bit, remove screws from the corner trim (Figure 5A).
10. Using a razor knife, cut the caulk (Figure 6A) around the roof line trim piece (Figure 6B), and then,
using a screw gun and a #2 square drive bit, remove screws (Figure 6C) from roof line trim piece.
A
A
B
C
A
Figure 5
Figure 6
11. Using the polystick, gently pry the trim
pieces from the top and upper corners.
Pull to remove the trim pieces and
discard.
12. Using the polystick, remove any caulk
still in place on the roof edge (Figure
7A).
13. There may be a few flat head screws
holding the top of the front metal
down. If so, using a screw gun and a
#2 square drive bit, remove those as
well.
14. Disconnect the upper marker lights
(Figure 4C) from the Wago connectors,
and then remove the lights from the
front metal of the unit and discard.
A
Figure 7
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 7 of 25
15. Remove the interior trim around the windshield. There are 4 flat pieces which can be gently pried
off as they are secured with double stick tape and Chem X adhesive (Figures 8A and 9A). There
are two other sections of trim that have screws securing it to the wall (Figure 10A). Remove those
screws using a screw gun and a #2 square drive bit. Discard all of the trim pieces. New trim will be
provided.
16. If there is an internal trim ring present around the windshield opening, use a screw gun and a #2
square drive bit to remove the screws holding it to the wall (Figure 11A). Remove the trim ring pieces
and discard. They will not be reused.
A
A
Figure 8
Figure 9
A
A
Figure 10
Figure 11
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 8 of 25
17. Place a piece of paneling over the opening of the windshield to prevent dirt and debris from
entering the unit. Make sure the fasteners used do not penetrate the front wall of the unit and that
they are placed in areas that will be covered by the interior trim.
18. On the outside of the unit, using the snap off utility knife with the blade extended to about 3 inches,
cut around and behind the windshield glass to separate the glass from the sealant (Figure 12A).
19. Using two people, peel the glass away from the unit and carefully set aside (Figure 13). If you are
replacing the windshield with a new one, discard the windshield. If you will be reinstalling the same
glass, the glass must be protected and have all old sealant removed from it and the mounting
surface cleaned. Take care to protect the graphics on the windshield as well.
A
Figure 12
Figure 13
20. Using a screw gun and a #2 square drive bit, remove the trim strips (Figure 14A) inside the
windshield frame and discard.
21. Using a screw gun and a #2 square drive bit, remove the screws (3) from the bottom lip of the rock
guard metal (Figure 15A), and remove the metal from the unit and discard.
A
A
Figure 14
Figure 15
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 9 of 25
22. Using a power drill and a 3/16” drill bit, drill out the rivets holding the metal retaining strip along the
front wall (Figure 16A). Discard the strip after removal.
23. Using two people, remove the upper wall metal from the unit and discard.
24. Using a razor knife, cut and remove the foil from the upper section of the wall structure (Figure 17A).
A
A
Figure 16
Figure 17
25. Remove the fiberglass insulation from the cavities in the upper section of the wall structure. Check
for any moisture. If there is any moisture, make sure that the interiors of the wall cavities are dry
before beginning reassembly.
26. Cut and fit pieces of the pink insulation (P/N 119851) into the cavities so that the insulation covers
the paneling surface inside each cavity and slightly goes up the side wall of the aluminum structure
(Figure 18A). Make sure the insulation does not extend onto the outer surface of the aluminum wall
structure as this will interfere with the new metal installation. Feed any wiring through the insulation
so it sits on top.
A
Figure 18
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 10 of 25
27. Using the eternabond tape (P/N 101610), cover over the front corners of the unit making sure that
the tape overlaps the previous screw holes from the corner trim (Figure 19A).
28. Using a screw gun, and square drive bit and four (4) 1/4”-14 X 3” self-drilling screws (P/N 113494),
install the 2x3 (P/N 100780) into the long center cavity under the windshield opening (Figure 20A).
You may need to trim the 2x3 to fit inside the cavity. The 2x3 should fit tightly into the cavity without
having to force the 2x3 into place. Forcing the 2x3 into the cavity could distort the wall structure.
A
A
Figure 19
Figure 20
29. Using the metal cutting shears, trim the corner of the side metal so that the front edge is even with
the lower front of the unit (Figure 21). Cover the cut edge with rubber edge trim (P/N 101033) (Figure
22).
Figure 21
Figure 22
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 11 of 25
30. Using two people, carefully place the new rock guard metal (P/N 114929) with the 4x8 sheet of
lauan (P/N 113538) against the front of the unit, making sure the lip on the bottom of the rock guard
metal is flush with the underside of the front of the unit (Figure 23).
31. Using the D10 stapler and staples, secure the top edge of the S-lock of the rock guard and lauan to
the aluminum structure of the unit (Figure 24).
Figure 23
Figure 24
32. Using a screw gun, a # 2 square drive bit, and ten (10) 1 1/2” black pan head screws (P/N 101338),
secure the bottom lip of the rock guard metal to the underside of the wall structure (Figure 25).
33. Cut pieces of the other lauan panel (P/N 113538) to fit over the cavities of the aluminum structure,
leaving the windshield opening clear. Secure them along the top and bottom edges with the D10
stapler and staples (Figure 26). Before securing the section of lauan over the marker light wires,
use a power drill and a step drill bit to drill a 1/2” hole through the lauan for the wiring to come
through.
Figure 25
Figure 26
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 12 of 25
34. Cut pieces of the foam tape (P/N 100996) to cover the staples used to secure the rock guard and
the lauan and stick into place (Figures 27A and 28A).
A
A
Figure 27
Figure 28
35. Dry fit the upper panel of metal (P/N 114641) into the s-lock of the rock guard metal and align the
sides of the metal with the sides of the front wall of the unit. Using a screw gun, a # 2 square drive
bit, and two (2) 1 1/2” black pan head screws (P/N 101338), temporarily secure the metal into place
(Figure 29).
36. Using a power drill and a step drill bit, drill a 1” diameter hole through the metal near the middle of
the windshield opening. This hole will be used to insert the metal nibbler into the hole to cut out the
windshield opening in the metal (Figure 30).
Figure 29
Figure 30
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 13 of 25
37. Insert the metal nibbler into the hole and cut around the windshield opening to rout the hole for the
windshield (Figure 21). Carefully remove the cut metal and discard (Figure 32).
38. Using a screw gun and a #2 square drive bit, remove the temporary screws from the upper metal
panel and carefully remove the metal from the s-lock and set aside.
39. Using an air nozzle or vacuum, clean out the s-lock to make sure there are no metal shavings or
other debris in the channel. Clean up around the newly cut opening as well.
Figure 31
Figure 32
40. Using the caulk gun and the 295 sikaflex sealant (P/N 105111), place a bead inside the s-lock of the
rock guard metal (Figure 33).
41. Lift the upper front panel of metal and set the bottom edge into the S-lock and pull down on it
to firmly seat it into the channel. Lay the metal against the front of the unit and again temporarily
secure it in place using the screw gun, a # 2 square drive bit, and two (2) 1 1/2” black pan head
screws (P/N 101338) (Figure 34). Make sure the metal is properly aligned with the windshield
opening before securing with the screws.
Figure 33
Figure 34
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 14 of 25
42. Before securing the top edge of the metal, install the new marker lights (P/N 100254).
43. Measure and mark the locations you measured in step 5. Using a power drill and a step drill bit, drill
a 1/2” hole in the metal panel (Figure 35A). Feed the wiring from the new marker lights through the
holes and connect the wiring to the Wago connectors (Figure 36). Test the lights to make sure they
are correctly wired before moving on to the next steps.
A
Figure 35
Figure 36
44. Make sure the windshield opening is free of any debris and then remove the paneling that was
secured over the inside of the unit.
45. Using a clean rag and isopropyl alcohol, clean the faces of the metal around the edges of the unit
and the windshield opening.
46. Using the eternabond tape (P/N 101610), seal around the windshield opening (Figure 37). Make sure
the tape overlaps the aluminum structure and the metal skin. Do not have the tape overlap itself at
the corners.
47. Using the eternabond tape (P/N 101610), seal over the edge of the newly placed metal from the roof
edge, to the bottom of the unit (Figure 38). Make sure to stretch and tuck the tape into the S-lock
channel at the top of the rock guard.
Figure 37
Figure 38
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 15 of 25
48. Dry fit the windshield shade (P/N 115694) in the opening and secure with quick clamps (Figure 39).
49. Using a screw gun, a # 2 square drive bit, and 1 1/2” black pan head screws (P/N 101338), secure the
frame of the shade into the wall structure (Figure 40).
Figure 39
Figure 40
50. Using the Sika sponge (P/N 115691), apply the Sika Primer (P/N 116081) to the metal and eternabond
tape around the windshield opening (Figure 41) and around the windshield itself on the interior face
(Figure 42). Stay outside of the black dotted area on the windshield when applying the primer. Allow
the primer to cure for at least 10 minutes before applying the sealant.
NOTE: If you are reusing the original windshield glass, make sure the glass is completely clean and
free of any residual sealant before priming.
Figure 41
Figure 42
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 16 of 25
51. While waiting for the primer to cure, install the corner trim pieces (P/N 111202 - Door Side Trim, P/N
111203 - Off Door Side Trim) using the screw gun, a # 2 square drive bit, and twenty (20) #10 x 1 1/2”
Self Drilling Screws (P/N 100891) (Figure 43). Remove the temporary screws that were installed in
the upper wall metal before installing the corner trim pieces. When installing these trim pieces, work
from the bottom up and do not over-tighten the screws into the wall structure as you will distort the
curvature of the front of the unit. Make sure the side flange of the trim is completely overlapping the
eternabond tape previously applied.
Figure 43
52. Install the roof line trim (P/N 105831) using the screw gun, a # 2 square drive bit, and 1 1/2” black pan
head screws (P/N 101338) (Figure 44). There is a longer leg and a shorter leg on the trim. The longer
leg goes towards the rear of the unit. The shorter leg goes towards the front of the unit (Figure 45).
Start the screws in the middle of the trim and work to the edges. Do not over-tighten these screws
as you will distort the line of the trim.
Figure 44
Figure 45
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 17 of 25
53. Using the caulk gun, lay a bead of white Alpha Thane sealant (P/N 100092) along the rear edge
of the top trim (Figure 46A). Then lay a bead of black Trem Pro 644 sealant (P/N 101006) along the
front edge of the top trim (Figure 46B). Then use black Chem X Adhesive/Sealant (P/N 100650)
along the side edges of the top trim where it meets the corner trim (Figure 46C).
B
A
C
Figure 46
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 18 of 25
54. Using a caulk gun and the SikaTack Ultrafast Sealant (P/N 115690) (heated to 160 degrees F), lay
a sharkfin shaped bead around the windshield opening on the front of the unit, over the area
previously primed (Figure 47). Anywhere there is a break in the application of the sealant and at the
corners of the opening, you must overlap the sealant by at least one (1) inch (Figure 48A).
A
Figure 47
Figure 48
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 19 of 25
55. Using three (3) people (one [1] inside the unit, two [2] to lift the glass), set the windshield glass (P/N
114099) into place over the sealant (Figure 49). The corners of the glass should be placed using the
measurements taken in step 4.
56. While the two people outside press the glass against the front wall of the unit and hold it in place,
the person inside the unit will be installing suction clamps to pull the glass against the wall and hold
it in place until the sealant cures (about 2 – 4 days [*see NOTE]) (Figures 50, 51, 52).
Figure 49
Figure 51
Figure 50
Figure 52
*NOTE: Click the link below or scan the
QR code to the right:
SikaTack Ultrafast Sealant Data Sheet
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 20 of 25
57. Lay masking tape on the metal face around the windshield to protect the metal while applying the
outside sealant (Figure 53).
58. Using a caulk gun and the Sikaflex 295 sealant (P/N 105111), lay a bead of sealant around the edge
of the windshield where it meets the front sheet metal (Figure 54A). Using your finger or a caulk
tool, smooth the caulk along the edge of the windshield to ensure a single, smooth seal around
the glass. Use a clean rag moistened with isopropyl alcohol to wipe any excess caulk from the
windshield glass.
A
Figure 53
Figure 54
59. Once the sealant has been smoothed against the metal, carefully peel off the painter’s tape to
create a clean finish of the sealant (Figure 55).
60. Lay a strip of masking tape along the joint of the S-lock and the upper metal panel, on the upper
panel (Figure 56A). This is to protect the upper panel from excess sealant.
A
Figure 55
Figure 56
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 21 of 25
61. Using the caulk gun and Trem Pro 644 sealant (P/N 101006), lay a bead of sealant along the S-lock
joint with the upper wall panel. Using your finger or a caulk tool, smooth the caulk along the edge
of the rock guard metal S-lock to ensure a single, smooth seal along that edge. Use a clean rag
moistened with isopropyl alcohol to wipe any excess caulk from the metal.
62. Once the sealant has been smoothed against the metal, carefully peel off the painter’s tape to
create a clean finish of the sealant (Figure 57).
63. Using the caulk gun and Trem Pro 644 sealant (P/N 101006), lay another 1” long bead of Trem Pro
644 up each side of the corner trim where it meets the S-lock of the rock guard (Figure 58A). Using
your finger or a caulk tool, smooth the caulk along the edge of the rock guard metal S-lock to
ensure a single, smooth seal along that edge. Use a clean rag moistened with isopropyl alcohol to
wipe any excess caulk from the metal.
A
Figure 57
Figure 58
64. Using the caulk gun and Trem Pro 644 sealant (P/N 101006), fill the hole behind the marker lights
with the sealant (Figure 59A) and then press the marker lights into the holes until they snap into
place (Figure 60). Use a clean rag with isopropyl alcohol to wipe any excess caulk from the metal
and the marker light.
65. Prepare the LED light strips (P/N 121426) for installation. There are two (2) pieces: the LED lights,
and the vinyl mounting track. Align the end of the LED lights with the wiring to the end of the track.
Using the polystick, press the LED lights into the vinyl track (Figure 61).
A
Figure 59
Figure 60
Figure 61
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 22 of 25
66. To install the LED lights onto the unit, remove the adhesive backing from the vinyl mounting track
(Figure 62A), and align the end of the track with the wiring coming out of it with the bottom edge
of the corner trim (Figure 62B) on the front of the unit. Press the track into the corner trim working
from the bottom of the unit to the top of the unit, making sure to keep the track straight and in the
middle of the trim.
67. Connect the LED light wires to the wiring under the front end of the unit using the blue cap scotch
lock connectors (P/N 101648) (Figure 63A). Test the lights to make sure they are wired correctly
before moving on to the next steps.
B
A
A
Figure 62
Figure 63
68. Wrap the connections in electrical tape and install new plastic wire loom (P/N 101459) around the
wiring.
69. Once the adhesive for the windshield has cured (about 2 – 4 days [*see NOTE]), remove the suction
clamps from the inside of the unit.
*NOTE: Click the link below or scan the
QR code to the right:
SikaTack Ultrafast Sealant Data Sheet
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 23 of 25
70. Apply double stick tape (P/N 108214) (Figure 64A) to the wider lip of the mounting side of the
horizontal trim pieces (P/N 114775) (Figure 64B), and using the caulk gun and Chem X adhesive (P/N
100650), apply blobs of the Chem X to the mounting side of the flat trim pieces (Figure 65A). Make
sure these blobs are tall enough to be above the lip on the trim.
A
B
A
Figure 64
Figure 65
71. Install the bottom trim piece to the wall in the same location the original trim was removed. Make
sure that it is parallel and level with the windshield opening and centered in the opening (Figure
66A). Press and hold the trim against the wall for 20 – 30 seconds to make sure it is bonded to the
wall.
72. Install the curved trim backer pieces (P/N 114776) (Figure 66B) with the longer side in the opening
and shorter side against the wall. Make sure they are at 90 degrees from the bottom trim and
parallel with the vertical of the windshield opening. Using a screw gun, a #2 square drive bit, and
two (2) #8-2 1/2” screws (P/N 100871) per side of the trim, secure the curved trim backer to the wall
(Figure 66C). Apply double stick tape (P/N 108214) to the backer pieces (Figure 66D).
73. Using the caulk gun and Chem X adhesive (P/N 100650), apply blobs of the Chem X to the
mounting side of the side trim pieces (P/N 114774). Install the side trim pieces over the curved
backer pieces making sure that they are parallel and even with the curved backer (Figure 67A).
Press and hold the trim against the backer for 20 – 30 seconds to make sure it is bonded to the
backer.
C
B
D
A
C
A
Figure 66
Figure 67
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 24 of 25
74. Install the top trim piece (same as bottom horizontal trim piece) to the wall in the same location the
original trim was removed. Make sure that it is parallel and level with the windshield opening and
centered in the opening. Press and hold the trim against the wall for 20 – 30 seconds to make sure
it is bonded to the wall.
75. If you reused the original windshield, clean all surfaces with the appropriate cleaners (see the
Interior and Exterior care sections of the Model I Owner’s manual [Scan QR Code Below]).
76. The installation is completed. If you installed a new windshield, you have to apply new graphics to
the front of the windshield.
77. The graphics should be applied in the same location as on the original windshield (Figure 68).
There are two pieces of the graphics: the conjoined triangles (P/N 113216), and the “BRINKLEY”
name plate (P/N 113215) . The name plate should be centered above the triangles. Use the
measurements from step 6 and apply the graphics according to those measurements (Figure 68).
Figure 68
78. Clean all surfaces with the appropriate cleaners (see the Interior and Exterior care sections of the
Model I Owner’s manual [Scan QR Code Below]). The installation is completed.
Scan QR Code
above for Brinkley
Owner’s Manual
Work Instructions: WI-011-2025 Model I Front Metal Replacement Instructions
Revision Level: REV G
Product: Model I
Page 25 of 25
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Last update on 2026-06-27 / Affiliate links / Images from Amazon Product Advertising API
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TSB/Document ID: WI-011-2025 REV G
Replacement Service Bulletin Number:
MFR Communication Date: 2026-07-24
MFR Internal Campaign ID/Software Version: WI-011-2025 REV G
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY
MFR Component System: Structure
MFR Component Subsystem: Front metal / window
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- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
Last update on 2026-07-02 / Affiliate links / Images from Amazon Product Advertising API
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