Removing the Old Lock - Installing the New Lock

AX HEAD LOCK - Removing the Old Lock:

Step 1 - Remove the “Hockey Puck” knob and foam ring from lid. Knob may need to be pried from its post. Pry knob using the rivet as backing, while rotating the knob. See illustration “A” (Caution: Be careful Not to damage paint surfaces.)

Step 2 - Drill out aluminum rivets using a 3/16” drill bit. See illustration “B”. Lock will remove from the bottom of lid.

Step 3 - Use “mineral spirits” or “lacquer thinner” to remove any glue and dirt from the site.

Note: Some marks left from previous lock and rivets may not be removable. Hole plugs are provided to fill rivet holes, but for the best look, filling the rivet holes and repainting the lid may be required.(optional)

“A”	“B”

Marking New Hole:

Step 1 - Place plastic “Hole Plugs” in the drilled out rivet holes.(supplied in kit)

Step 2 - Place “Rubber Gasket”(supplied in kit) evenly between both “Hole Pugs” with the inside of the rubber gasket aligned with the top of the existing hole. See illustration “C”

Note: Gasket may slightly overlap hole plugs in order to align “Rubber Gasket” to top of hole. Gasket may also over lap top of lid hole slightly. See illustrations “C” & “D” .

Step 3 - Secure “Rubber Gasket” with four small pieces of tape as seen in Illustration “D”.

Step 4 - Mark with a marker the “Inside” of the “Rubber Gasket” as seen in
illustration “E”.

Note: On black or darker paint a white marker or scribe may be used.

“C”	“D”	“E”

Cutting New Hole:

Step 1 - Remove “Rubber Gasket”.

Step 2 - Align a 2 3/8’’ Hole Saw (Not provide in kit) over the marks as close as possible as seen in illustration “F”.

Note: Tape may be place on the top of the lid around your working area to prevent any paint damage.(optional) Hole Saws are available at your local hardware store. A hole saw made for cutting metal or wood works good. A rotary tool may also be used to cut fiberglass.

Step 3 - Slowly seat the pilot hole part of the “Hole Saw” first. After the pilot hole is drilled, continue with the larger portion of the drill bit , staying as close to the marked lines as possible.

Tip: After seating the pilot hole slowly, a higher speed on the drill works better for cutting the large portion of the hole.

“F”	“Finished Cut Hole”

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Removing the Old Lock - Installing the New Lock

AX HEAD LOCK - Installing the New Lock:

Step 1 - Place “Rubber Gasket” between lock and fiberglass (ridge side up, flat side down) place lock in the hole.

Step 2 - Hold lock in place while placing "Spacer Block" on and screw on large plastic -Lock Nut on under side of lock.

Note: Thick edge of “Spacer Block” goes next to large plastic “Lock Nut”, Thin edge faces up towards fiberglass. Tighten lock snugly but allow play for adjustment.( see Adjusting:) Hand tighten the lock firmly to the lid while final alignments are made.

! ! ! Lock Will Not tighten properly if the “Spacer Block” is not installed correctly.

“G”	“H”	“I”

Adjusting Lock Catch and Lock

Step 1 - The Original locks catch (or L-bracket) attached to inside of the bag will be used. The "L-Bracket" must be moved down One hole on the bag, and a new hole drilled in the bottom. The top hole on the bracket moves to the bottom hole on the bag. "A" moves to "B", "B" moves to "C". (see illustration "G") Straighten the L-Bracket as some have a slight bend to them. Bracket should lay flush against bag in a straight up and down position.

Note: Tighten top nut securely, but Do Not drill bottom hole until final adjustments are made.

Step 2 - With the Ax Head Lock in the closed or locked position, position the “Lock Bar” facing the L-Bracket. (See illustration “H”) Caution: Hand tightening is usually sufficient . If lock Does Not tighten properly make sure “Spacer Block is installed properly . Do Not over tighten.

Step 3 - Once proper alignment is achieved (as seen in Illustration "H") drill bottom hole of the L-Bracket (illustration "G") and securing it to the bag.

Note: Tighten top nut securely and leave bottom nut finger tight.

Final Adjustment

Step 1 - With both nuts attached to the “L-Bracket” tighten snugly but allow room for slight play while making final adjustments.

Step 2 - Final adjustment is achieved by moving “L-Bracket” slightly from side to side and or up and down. Also rotating the lock slightly may be necessary to achieve proper closure. The Tab or Ear on the "L-Bracket" may need to be bent slightly down to achieve a tighter seal on the lid. (illustration "I")

Hints and Tips: Lock will function BEST when turned LEFT to LOCK and RIGHT to UNLOCK. This is mainly do to the factory divot on the left side of the “L-Bracket”. Perfect alignment is achieved when the “Lock Catch” hits the divot and is in the closed or down position. The L-tab or Ear on the “L-Bracket” mat be bent slightly down to achieve a tighter seal on the lid The New “AX HEAD LOCK” functions with a ¼ turn to the Left to Lock and ¼ Turn to Right to Open.

LEFT to LOCK , RIGHT to RELEASE.

The most difficult part of the installation is probably achieving the proper final adjustment.
The locks movements will become smoother as wearing occurs / a slight film of grease on the underside of the "L-Bracket" gives the lock a smoother action (optional) / HDPoliceSpecialties.com and "Ax Head" Locks are not responsible for any damages that occur during installation.

Removing the Old Lock - Installing the New Lock