Specifications

FCS1362 Page 26 of 74 © Nov 2010
o Refer to section 4.8.1 for the measurement test requirements
• Measuring tape
• Power drill kit
• Cone cutter
• RF connector ratchet crimp tool
• DC connector ratchet crimp tool
• Portable soldering iron
o Battery operated irons are preferred. Gas powered soldering irons may not be suitable for
some environments or vehicles particularly petrochemical or hazardous load vehicles.
o Open flame torches of any kind are deemed to be dangerous and a fire risk and so should not
be used
• Heat gun. This is required for heat shrink materials and connectors
o A soldering iron is not suitable for use with heat shrink materials
• Vehicle trim removal tools
• Radio removal keys
• Specialised screw or security driver bits
• Seat and panel covers to protect the vehicle during installation procedures
• Storage for any parts, screws or fixings removed during installation for later reassembly
2.11. Drilling holes
All holes and cuts made in materials
• must be de-burred with an appropriate tool
• Have all sharp edges removed with an appropriate tool
2.11.1. Preparation for drilling holes
Very careful consideration needs to be taken in the case of double skinned panels and/or structural
panels as to whether to proceed with creating a hole. Check it is safe to drill through both skins and that
there is access to both sides to ensure correct sealing and protection.
Prior to drilling a hole a check must be carried out as to what is located behind the material to be drilled.
Care must be taken to avoid items such as petrol tanks, fuel lines, braking components, battery cables,
wiring looms, air bags, electronic modules, ventilation pipes, etc.
It is recommended that no holes should be made through the under body of the vehicle. Where this is
unavoidable adequate anti-corrosion precautions must be taken and the customer advised this may affect
vehicle corrosion warranty.
2.11.2. Hole drilling
A mark for the point to be drilled must be made prior to drilling.
The appropriate speed of cut and bit/cutter should be selected based on the hole size and material to be
worked on.
Drill bits/cutters should be fitted with a 'stop bit' to avoid inadvertently drilling beyond the required
measured depth.
Drilling through carpets should be avoided to prevent snagging or pulling.
When drilling is complete, any metal swarf should be removed carefully from the vehicle to prevent
scratching the vehicle bodywork.
2.11.3. Hole sealing & protection
Holes drilled through metal panels must be treated with a suitable anti corrosion treatment such as zinc
based touch up paint.
Any drilled hole that may allow dirt or water through must be sealed with a waterproof, flexible sealant.
Holes through which cables pass must be fitted with a suitable cable protection such as a grommet.