Tommy Docks 4003 Dixie Ave, Wausau, WI 54401 Phone : 715-842-3804 Toll Free : 866-675-1880 Fax : 715-842-3420 Aluminum Dock Frame Assembly Instructions www.tommydocks.
Aluminum Dock Kit Components 48” End Rail Qty 2 Side Rail (96” of 120”) Qty 2 Center I-Beam (96” or 120”) Qty 1 23 7/8” Intermediate Crossmember Qty 2 Hardware Self Tapping Screw Qty 2 Stainless Steel Hex Head Bolt Qty 20 Stainless Steel Tapered Head Screw Qty 20 Stainless Steel Nylon Locknut Qty 40 Tools Power Drill 3/8” Box End Wrench 5/16” Driver Bit #2 Phillips Bit Hex Bit
1 Start by sliding the two (2) Side Rails into the End Rail (1a). The End Rail fits in between the flanges on the Side Rail (1b). End Rail Side Rail Side Rail 1a 1b Side Rail End Rail Flange of Side Rail 2 Insert the Tappered Head Stainless Steel Screws at the corner (2 screws per corner) (2a). Hand tighten the Stainless Steel Locknuts to all (4) corner screws at the top side of the frame (2b).
3 Insert the center I-Beam into the End Rail as shown (3a). Make sure notch in I-Beam engages Top Flange of Side Rail (3b). The top flange of the I-Beam goes on top of the End Rail Flange and the Bottom Flange of the I-Beam sits on top of the Bottom Flange of Side Rail (3c). Insert the screws and locknuts (3d) and hand tighten (3e).
4 Install one Intermediate Crossmember I-Beam into the Side Rail (4a). Notice that the Intermediate Crossmember fits in between the flanges on the Side Rails (4b) but not where it attaches to the center I-Beam (4c). Attach with the screws and locknuts (4d) and hand tighten (4e).
5 Notice that the bottom flange of the Intermediate Crossmember I-Beam fits underneath the bottom flange of the center I-Beam (5a). Insert the screws and lock nuts (5b) and hand tighten (5c). Attach the second Crossmember in the same manner as the first, but do not install the screws into this side rail yet.
6 You now have all the frame components attached to the frame except the last End Rail. Make sure all of the connections are fitted tightly and tighten all of the screws you have installed so far on the top side of the frame. Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while holding in place the Stainless Steel Nylon Locknut with a 3/8” Box End Wrench.
7 This illustration shows the installation of individual deck boards into the first half of the frame (7a). (Disregard this step and the next step if you will be making removable deck panels.) Once you are at the halfway point, install and tighten the screws and locknuts that attach the remaining Intermediate Crossmember (7b). Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while holding in place the Stainless Steel Nylon Locknut with a 3/8” Box End Wrench.
8 Install the remaining deck boards into the frame. 9 Fit one end of the remaining End Rail into the Side Rail (9a). The End Rail fits in between the flanges on the Side Rail (9b).
Insert two (2) Truss Head Stainless Steel Screws at the corner (10a) and hand tighten (10b). Truss Head Stainless Steel Screw 10a Stainless Steel Locknut 10b 2x 11 2x Make sure the top flange of the I-Beam goes on top of the End Rail and the bottom flange of the I-Beam sits on top of the bottom flange of End Rail(11a). Insert the screws and locknuts (11b) and hand tighten (11c).
12 Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while holding in place the Stainless Steel Nylon Locknut with a 3/8” Box End Wrench. NOTE: When assembling the frame components, if you encounter holes that do not line up exactly, it is acceptable to use a drill to ream out the holes slightly for the fasteners to fit appropriately.
14 Slide the last board into the frame and you will be able to flex the remaining corner connection to snap in the last deck board (14a). You may now push the remaining corner together (14b). 14b 14a 15 The final top of the frame corner connection is made by installing the (2) Self Tapping Screws provided (15a). Fit corner together tightly and tighten using 5/16” Driver Bit (15b).
16 Flip the frame over to install the remainder of the fasteners into the frame. Where indicated install Stainless Steel Hex Head Bolt and Stainless Steel Nylon Locknut (16a). Use the 5/16” Driver Bit to fully tighten the Stainless Steel Hex Head Bolt while holding in place the Stainless Steel Nylon Locknut with a 3/8” Box End Wrench (16b).
