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INSTALL INSTRUCTIONS KK-100-05 & KK-120-05
KWIK-KIT PRISONER TRANSPORT INSERT
FORD and CHEVY VAN PRISONER TRANSPORT
TOOLS REQUIRED:
¼” & 3/8” Ratcheting Wrenches Awe or Scribe
¼” & 3/8”Air Ratchets (recommended) Pry-bar
3/8” Impact Guns (recommended) Wire Crimping tool
¼” & 3/8” Standard Socket Sets Wire Stripping tool
Powered Drill Wire Cutter
Powered Screwdriver (recommended) Table/Circular Saw (if necessary)
Drill Bit Set Utility knife
Tape Measure Caulking gun
Screwdriver Se
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40” COMPARTMENT (cont): QTY DESCRIPTION PART # USED FOR: 40 #10 x 1” Phillips pan head sheet metal screw GSM33196 Floor, wall to ceiling 25 #8 x 3/8” Phillips flat head screw GSM33179 Vent plates/dome lights 5 ½” Flat washer GSM31009 Grab straps/seat belts 5 ½” Lock washer GSM31030 Grab straps/seat belts 5 ½” x 1 ¼” Socket button head bolt GSM33310 Grab straps/seat belts 5 3/8” x 2” Hex head bolt GSM33032-1 Bulkheads 5 3/8” Hex nut GSM30008 Bulkheads 5 3/8” Lock washer GSM31028 Bulkhe
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Rear OEM Trim modifications 1997-2007 Chevrolet G-Series Van Installation of Kwik Kit is very similar in Ford and Chevy Vans. All kits start with a measurement at the rear floor. The rear plastic floor trim on Chevy vans must be cut straight across as shown in photo. Measure seven inches ( 7” ) from rear center of trim and cut straight line full width. (Jig saw works well for this step) After plastic trim is cut and back in it’
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Ford Van Driver-Side rear Ford Van Passenger-Side rear 8” to 8 ½” Note: Exact position may not be 8”inches to rear body flange. Note: The OEM rear Black square to Driver side if van has OEM rear Air plastic trim will remain. Photos show without Trim. conditioning Note: Photos above show a Chevrolet Van. Photos are intended to show rubber floor mat option only. PASSENGER WINDOW VAN PREPARATIONS: 1. Remove all rear bench seats
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1. Remove clear shrink- wrap covering the prisoner transport assembly. 2. This is the rear 40/60/or 80 section of the kit. 3. Remove all black hardware, wood panels and brackets holding wood panels. 4. Remove bolts holding the kit to the wood pallet. 5. With all hardware removed the remaining sections should match the sub-assemblies on the following pages 1. Remove clear shrink-wrap covering from prisoner transport assembly. rd 2. This is the 3 compartment, 40 section 3.
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Remove all black hardware from assembled unit. This will give you the subassemblies as they are shown on the following pages. KK-XXX-05_INST_8-07 6
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The following photos are the main subassemblies as they are shipped from the factory. Remove drawing on final page and reference the item #’s as you install this kit. Item #1 Item #2 Item #3 Driver Side Bench/Wall/ Passenger Side Rear Bench/Wall/ Front Bulkhead minus driver-side rd Front bulkhead wing section 3 Compartment Bulkhead Wing section Wing section Item #4 & 13 Item #5 Item #7 Driver-side ceiling (2) - Diamond plate floor Center Divider Item #8 Item #9 Item #10 rd rd Pas
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Item #12 Item #6 Item #11 rd rd Rear bulkhead/door assembly 3 Compartment ceiling 3 Compartment Bulkhead/door assembly KWIK KIT LAYOUT Diamond plate floor and ceiling sections are not shown for detail purposes. KK-XXX-05_INST_8-07 8
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VERY IMPORTANT: Be sure that all Auxiliary lighting, video systems, Kwik kit options, and wiring are complete. Access is severely limited after kit is installed. Notch trim for wiring “B” Pillar 1 ½” Hole If optional rear load light(s) Run all wiring for dome lights, power For neatness of wiring, route all (KK-RLL) was ordered, install at vents, video system, HVAC, etc. at cables down driver-side “B” pillar. this time. this time. Tie to existing OEM harness If going under hood for
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Item #1 Item #2 Place Driver-side Bench/Wall Place Passenger-side assembly into van so bench rests Bench/Wall assembly into van so on wheel well bench rests on wheel well Item #3 Item #3 Remove steel support bracket for Remove Emergency Exit Hatch Emergency Exit Hatch pin. Re-install from Front Bulkhead to ease when attaching Front Bulkhead to installation Bench/Wall assemblies Item #3 Item #3 Item #3 Place Front Bulkhead into Attach Front Bulkhead to View of Emergency Exit H
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Item #4 & #13 Place (2) Diamond Plate Floors Be careful that exposed wires are not touching metal and optional KK- between Bench/Wall assemblies and x-VAK hoses are not completely crushed Front bulkhead. Place cardboard along side of bench while positioning Note: Vent hose will be tight in spots. If hose are crushed to an oval the floor to avoid scratching the bench. shape the airflow will still be good. Avoid completely crushing hoses. Item #5 Item #5 Item #3 Item #4 Place Center
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Item #8 Item #8 Place Passenger-side Ceiling section Route dome light wires, HVAC Current view of installation into vehicle hoses, video cables, etc to their Do not attach any hardware at this time respective locations Item #7 & #8 Item #12 Item #7 & #8 rd Position 3 Compartment Slide the ceiling sections out of the way in order to access A/C hoses, wires, etc. Note: These components will be hard to access once ceiling is mounted. Ceiling into vehicle. Remove all slack from hoses
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Item #10 to #9 Item #10 rd rd rd Place 3 compartment bench Bolt 3 Compartment Bench to 3 Compartment Divider using ¼” x ¾” Photo shows optional storage door Note: Be careful not to scratch bulkheads. carriage bolts and serrated nuts. Nuts should be on the inside of the bench Items #9, #8, & #12 all bolt together VERY IMPORTANT!!! Item #9 to #5 Items #9, #8, #12 rd Position 3 compartment ceiling and loosely attach a few Re-install screws removed in step rd ¼” x ¾” hex head bolts a
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Item #6 to #5 Item #6 Item #6 Place Rear Bulkhead Position between Driver and Loosely attach Doorframe to Center Doorframe into vehicle Passenger-side Bench/Wall divider using #10 x 3/8” flat head assemblies machine screws and nylock nuts Item #6 to #2 Item #11 Note: It is recommended to put rd Loosely bolt Rear Bulkhead Place the 3 Compartment edge molding on the OEM door Doorframe (at the door hinge) to Doorframe assembly. opening on the passenger side to Bench/Wall assemb
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Item #6 Item #7, #8, #12 to #3, & #6 to #5 Continue around the entire kit bolting An awe or scribe will help Tighten screws holding Rear all Ceiling pieces to Bulkheads and align the holes Doorframe to Center Divider Doorframes using ¼ x ¾” carriage bolts, washers, and serrated nuts Pry bar Cut door gasket with utility knife. Cut gasket to the length Position the entire unit according to the of door acceptor frame. Attach as shown above. measurements on the following page. Note
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Top Passenger-Side rear Top Driver-Side rear Item #6 Item #6 3” to 3 1/2” 3” Item #7 to #1 Item #6 Item #6 With unit positioned according to measurements on previous page, pre- Position Driver-side Ceiling section to drill and attach a #10 x 1” sheet metal screw to hold the rear Bulkhead in mate with Bench/Wall assembly. Pre- place while assembling the remainder of the unit. drill 5/32” holes into Ceiling, using Bench/Wall assembly holes as a guide. KK-XXX-05_INST_8-07 16
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Be careful when pre- drilling not to hit hoses, wires, etc… Note: Ceiling is behind wall Item #8 to #2 Item #5 & #4 to van floor Pre-drill ceiling with 5/32” drill bit and attach #10 x Be Sure Floor Is Square To Benches & Bulkheads. 1” Phillips pan head sheet metal screws to hold Attach Divider to vehicle. Pre-drill through floor(s) Ceiling to Bench/Wall assembly. Repeat these steps using 3/16” drill bit and attach using ¼” x 1 ½” hex head lag bolts on the Passenger-side Ceiling sec
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On the Rear doorframe, remove the sheet metal screws installed earlier. Drill 3/8” holes through the doorframe, floor, and vehicle. Attach using 3/8” x 2” hex head bolts, washers, fender washers, lock washers, and hex nuts. Item #6 to van floor Item #11 to van floor 3/8” x 2” Hex head bolt, washers, and nut Item #11 to van floor rd On 3 Compartment Doorframe repeat the same steps done on Rear Doorframe. Only one bolt is used and must be located just to the left of the doors hinge
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Socket Ball Item #14 to doors and frames Attach Ball & Socket Style Doorstop. st 1 Attach “Ball” portion of assembly. Attach to threaded hole on the door using a ¼” x 1” Hex head bolt. nd 2 Attach the “Socket” and bracket portion. Attach to doorframe using #8 x ¾” Phillips machine screws and keps nuts. Item #11 Item #15 In the upper corner of each side Silicone all seems and joints. Place trim panels as shown above rd of the 3 Compartment This will allow the unit to be Pr
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FINAL INSTALLATION PHOTOS Optional Storage Compartment Optional Storage Compartment (Sold Seperatley) (Sold Separately) KK-XXX-05_INST_8-07 20
