Big Air Fusion Tower Guida rapida
www.bigairwaketowers.com
Fusion
FusionFusion
Fusion
Tower
TowerTower
Tower
Installation and Instruction Manual
Installation and Instruction ManualInstallation and Instruction Manual
Installation and Instruction Manual
(Rev A)
Big Air Waketowers
Big Air WaketowersBig Air Waketowers
Big Air Waketowers Inc.
Inc. Inc.
Inc.
5305 Ro ert Lee Rd
5305 Ro ert Lee Rd5305 Ro ert Lee Rd
5305 Ro ert Lee Rd
Duncan, OK 73533
Duncan, OK 73533Duncan, OK 73533
Duncan, OK 73533
580
580580
580-
--
-252
252252
252-
--
-5314
53145314
5314
Toll free: 855
Toll free: 855Toll free: 855
Toll free: 855-
--
-252
252252
252-
--
-5314
53145314
5314
www. igair
www. igairwww. igair
www. igairwaketowers
waketowerswaketowers
waketowers.com
.com.com
.com
IMPORTANT NOTES FOR INSTALLING
YOUR BIG AIR TOWER
•The Fusion Tower is designed to fit a hull between 58” and 103” wide.
Please measure your intended mounting locations to make sure they fall
within this range.
•ALWAYS apply a layer of grease to all bolts before attaching to the joining
connection (some connections will call out blue Loctite).
•To avoid galling or binding, apply a layer of grease onto tubing before
inserting into the H-member. We understand it is a bit messy, but it cleans
up easily.
•If the hull is less than 3/8” thick in base mounting area then the hull will need
to be reinforced. You may use marine grade plywood, aluminum sheeting, or
a fiberglass kit. Contact us for a reinforcement kit.
•Never use the tower to pull inflatables.
•Read over the last page of the manual before drilling.
•Call us toll free if you have any installation questions at 855-252-5314.
Thank you for purchasing Big Air’s Fusion Tower. Installation of the tower is relatively
simple and should take two people 3 to 6 hours. You will need someone to help you
measure and assemble the tower. No special tools are needed other than those listed
below.
Tools Needed
Level
Tape Measure
Variable speed drill
Metric Allen wrench set
Standard Allen wrench set
9/16" Drill it
7/16" Drill it
Ratchet Strap
Masking Tape
Lithium grease
Metric Wrench set
Standard wrench set
Fusion Tower - Parts list
Loc # Part # Qty Description
1 AF-1001 1 H-member
2 AF-1002 2 Front Leg
3 AF-1003 2 Rear Leg
4 AF-1004 4 Front Corner
5 AF-1005 2 Rear Corner
6 AF-1006 1 Left Strut
7 AF-1007 1 Left Strut End
8 AF-1008 1 Right Strut
9 AF-1009 1 Right Strut End
10 AF-1010 4 Hinge Joint
11 AF-1011 1 Spanner wrench
12 AF-1012 4 Heim joints
13 AF-1013 4 Swivels
14 AF-1014 4 ase mounts
15 AF-1015 4 backer plate
12 AF-1016 8 Gaskets
13 AF-1017 4 Quick release knobs
14 AF-1018 8 ase bolt - 12mm
15 AF-1019 8 Nylock 12mm
17 AF-1021 4 Swivel olts
18 AF-1022 4 3/8" x 1" olt
19 AF-1023 2 3/8" x 1.75" olt
20 AF-1024 12 5/16" x 3/8 Set screw
21 AF-1025 12 3/8" set screw
22 AF-1026 4 5/16x3/4 set screw
23 AF-1027 4 collets
24 AF-1028 1 Spanner Wrench
Logo plates
Corner
Front Leg
Rear Leg
H-member
Base
Base bolt
Gasket
Base plate
14mm nylock
Swivel
Swivel mount bolt
Heim joint
Quick Release Knob
Step # 1. Decide where to locate your tower
.
•The Fusion can face either direction based on your preference.
•You can mount your tower anywhere along the boat’s hull where there is access
under the gunnel to install the backing hardware. We recommend you evaluate
what looks best for your boat and your style and were access makes installation
possible. Also, make sure to consider where the tower will rest if you lay it down.
•The front to back stance of the tower is approximately 70 inches long.
H
-
member
Rear Corners
Note: shorter
length
Front Corners
Note: longer
length
H-member
Right hand
threads
H-member
Left hand
threads
•Level the floor of your boat. (typically done using your trailer jack)
•Typically it’s best to mark the location for the rear leg mount on the side of the
gunnel and wait on the front leg locations.
•We suggest you use masking tape to cover the area where you will be placing the
mounts. This prevents scratches on the boat’s gel coat. Mark the EXACT
position of all the holes of the base plates.
Step #2: Drill the mount holes
Before drilling holes in your boat, make sure where the holes will go can be accessed
from inside the boat. This typically should not be a problem. If it is, then move the
tower forwards or backwards as necessary.
See our drilling guide at the end of
these instructions.
•Drill a 9/16” hole for each mount.
•You can use your gasket as a guide for your drill center
•Make sure to run your bit in reverse.
•It’s best to drill a 1/4” pilot hole first, then the 9/16” hole.
•If your hull is less than 3/8” thick, you will need to reinforce with additional
aluminum, fiberglass, or marine grade plywood.
Step #3: Install Rear Base Mount Bar Assembly
•Install the base bolts into the base using an allen wrench inserted into the end and secure
tightly (use blue Loctite on threads into the base)
•Secure the bases using a rubber gasket and the aluminum plate retained by the 12mm
nylock nut.
•You can bend the plate with a hammer if needed to match the interior profile of your hull
•Do this to both rear mount locations.
Step #4: Install Rear Swivels
•Attach the swivel to the base
using the swivel bolt. Do not
tighten excessively.
Base Mount
Base Bolt
Gasket
Rectangular Backer
Plate
Nylock
Swivel
Base
Quick Release
knob
Heim
Step #5: Assemble Tower Structure
(Careful, don’t slide the legs in too far or you may damage the finish of pipe that
will be exposed when installation is finished.)
•We recommend that you mark each corner with a sharpie marker showing the
distance from the end to the corner. This can easily be wiped off later with brake
cleaner.
•Install the heim joints half way into the bottom of the legs (make sure to
coat the threads with grease) (by threading half way in, you have some
level adjustment)
•Slide a hinge joint onto each leg as shown in the picture below (note: struts
should not be installed yet)
•Attach the front legs to the front corners using the set screws.
•Attach the rear legs to the rear corners using the set screws and the 5/16” pin.
Note: The rear leg uses a detent pin to help resist rotation from side loads. (The
pull ring should face towards the front leg.)
Hinge Joint
Detent pin
Port Strut
Rear Corner
Corner End
•Remove the threaded ends from the H-member. (Note, the left/port side threads
are left handed.)
•Slide the left hand threaded caps on to the port/left hand corners.
•Slide the right hand threaded caps on the starboard/right hand corners.
•Slide a collet as shown onto each corner end.
•Slide the rear corners into back tube of the H-member (the rear tube has the head
welded on) so that the end of the corner at a minimum passes past the set screw
ring on the H-member.
•Stand the tower up on the ground and use the set screws in the H-member to
secure the corner temporarily.
•Measure the width/distance across between the base mounts. (Do not worry if you
are unable to attain your exact mounting width at this time, you will pull the
structure inward more during installation)
Collet
Threaded cap
•Install the strut braces
•Adjust the tower to match the approximate width of the base mounts.
•Place the tower on the boat connecting at the rear mounts using the quick release
knobs.
•Approximately level the top of the H-member to match the floor. (you will need
to tie the tower to some type of overhead structure during this process)
•Attach a base to the front legs (make sure the front legs are aligned similarly on
each side)
•We recommend pulling the legs slightly forward to create some tension, then
mark the mount locations for the front base mounts.
•Use a gasket to mark drill hole locations for the front mount.
•Drill front mount holes.
•Install the front bases.
•Attach the tower to the bases using the swivels and quick release knobs.
Starboard/right
Side strut
Port/left
Side strut
BOW
Hinge
Joint
Starboard/right
Strut end
Port/left
strut end
Indice
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