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Step 1. Cutting the holes
Measure down from the underside of the top of the case 2in. Draw a line the length of the case from front to back referencing this measurement. Using this line drill a 1in dia. hole 1½" down from the front of the case. Drill another hole the same size 1½" from the center of the first hole. Moving down the reference line drill your last hole for the web strap handle 4¼" from the center of the first hole. Drill this hole using a ½" drill bit. Reference drawing
Step 2. Installing Web Handle
Insert the web strap into smallest hole. Pull inside case enough and tie a knot in the strap. The knot is on the inside of the case. Working you way to the front of the case, feed strap into next hole so it goes inside the case. Pull out through the hole closest to the front of the case and across front of case to the other side. Feed through the holes on that side and tie another knot to secure to case. Pull on the web handle to make sure your knots are secure.
Step 3. Cutting Speakers Holes
The kit will hold 4in speakers. Place your speakers side by side to the rear of the kit. Let them lay flat and rest centered in the case. Mark the bolt holes with a pencil. Next drill a 3/16" hole for each marked hole. Once all 8 screws are drilled flip the unit over and mark the speaker hole center. See illustration. Use the lines you drew to find the center of each speaker. Center punch the center and drill with a 3½" Drill bit or use a jig saw. NOTE: Drill slow or cut slow the ABS casing to prevent the material from melting. Once both speaker holes are cut, flip the case over and install the grills using the supplied screws. Place one speaker at a time over the 4 protruding screws and tighten using the lock nut bolts. Complete the other speaker as well. Place speakers with the terminals to the front of the case. This makes for easy hook up.
Step 4. Mounting Antenna
The antenna is easy mounted with a 3/8in hole. It can be mounted to either side of the case. We choose the left side closer to the bottom of the case. See pic. Once hole is drilled sandwich mount the antenna. Tighten the antenna and position the angle you like.
Step 5. Size the DIN hole in case
The case needs to be sized to accept a standard DIN size stereo. See illustration. Remove the sleeve from the radio you are using. Use this sleeve to mark the width of the casing that needs to be trimmed. The radio is mounted in the upper portion of the case, so align the sleeve in the upper opening. Trim with a file, razor knife or any suitable cutting device. Cut this very accurate and not beyond the necessary marks. The sleeve will insert easy when size is proper cut. Only the sides will need to be trimmed.
Step 6. Prep additional insert kit
Break off any tabs that keep this insert from setting flush on bottom of case or sides. Break off these tabs. This insert can be glued if you like or use the radio sleeve to secure it. Place on the inside of the case with the DIN opening at the top. This should line up with the trim work you did on the casing. Slide the radio sleeve through the front and through the insert. Use the sleeve tabs to secure it insert, sleeve to the main box casing. Once insert is secure snap in place the small hole cover.
Step 7. Power Cable Assembly
Cut off the end you don't need. For wiring specs the RED is 12volt + and the BLACK is negative 12 volts or ground. Route the cable through on of the holes on the back of the casing. Use the supplied cable clamp under one of the speakers screws to secure it to the casing. This keeps the power wire from pulling out of the case. This step is very important. Do not skip this step. Selection of which end to cut off is based on what type of hook up you have on your vehicle. All your power will be hooked to the RED and BLACK wire. Both the red wire and the yellow wire for the stereo are hooked to the power wire RED. This for some radios will drop your clock memory and station settings but not on the Jensen line of the radio we use. They have a built in nicad battery.
Step 8. Case Bottom
Now is time to cut and drill the bottom. Lay the casing on the sheet of ABS. Align 2 of edges and mark the rest. Mark around the radius ends as well. Cut away the excess with a razor knife and round off the edges. Reposition it under the case again and mark the mounting holes. Mark as many as you want to secure the bottom. We have supplied 8 nuts and bolts to secure the two together. Close the casing up after all the wiring is done and tested. Now would be the time to add the rubber feet or a bracket before it is secured to the bottom of the case.
Step 9. Wiring
Connect the radio and accessories you have in the box to your power wire. Run the speaker wires to the speakers and make that connection. Make sure that no wires are resting on the speaker paper. Use wire ties to secure the wires if necessary. Hook the build up before you close it up. Once you are sure that all is well secure the bottom. Congradulations you have a custom build Delivery Truck Radio
We use Dynamant™ in our PTUNES1 & PTUNES2 units. This improves the overall sound to the unit. It adds a little weight to the unit. If sound is important we do suggest it. Enjoy your Delivery Truck System
EASY TO FOLLOW STEPS FOR THE BASIC DELIVERY TRUCK RADIO KIT