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Old 08-02-2008, 02:51 PM   #1
Tcape
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Pop & Lock Installation

First thing I want to say is a big THANK YOU to Joe (Pizza Man) for making the P&L group buy possible. He got us a great price, and did all the hard work....getting our orders, getting the locks shipped from the manufacturer, then mailing them out to us. Standing ovation to you, Joe! (I'm standing as I type this. )

I'm starting this separate thread for the Pop & Lock installation so it won't get lost in the "P&L Ordering" thread. Hopefully, folks will post their ideas and tips for the P&L install. Here are some things I encountered that might be helpful to others as they do their own installation.

1. The instructions which come with the lock (and Joe helped write) are very good. The instructions AND a very good picture of the installation are here.... http://www.ridgelineownersclub.com/f...17-post12.html and I've also included the pic with this post.

I printed the pic of the installed lock (the one showing the workings of the lock system inside the tailgate), and it was tremendously helpful to look at when I was installing the lock. Nice to see exactly what it's supposed to look like.

2. This post by edarnoldnet was also very helpful with the installation..... http://www.ridgelineownersclub.com/f...tructions.html Very good tips to aid with installation and supplement the instructions.

3. In step #2, be sure you read the part about exchanging the bolts holding the bracket. Be sure to note that you can exchange the bolts you take out with the bolts you'll also take out in step #6. This is clearly covered in the instructions, but I almost overlooked it. If you don't exchange the bolts, the washers on the ones you initially take out won't let the bolts fit when the new bracket is installed.

4. The drill bits recommended for the installation are unusual sizes, and I didn't have either size recommended. However, you can easily substitute drill bits that are close to the sizes recommended. Just use the holes in the bracket as your guide, and pick bits that will fit OK through those holes.

5. Biggest problem I had was re-installing the tailgate cap. Took me almost 30 minutes to get the d*mn thing back on right!! In fact, that took longer than installing the lock. Be sure to look at how the plastic cap is made, and how it fits on the white clips. It has to be positioned just to the right of the clips...so the openings in the cap fit over the clips, then it slides to the left to lock into the clips. You may need to push your hip against the middle of the cap to make sure it doesn't bow in the middle.

If anyone has any additional tips for re-installing the tailgate cap, I'm sure they'd be appreciated. I was unprepared for how big a hassle that was. At least for me.

The entire install took me about an hour and fifteen minutes, but I took my time and went slowly. And a big part of my time (20-25 minutes) was spent trying to get the tailgate cap back on. Installing the lock is actually pretty simple. It all fits together very easily. Again, having the picture (mentioned above) was very helpful. Even if you're not too mechanically inclined, you should be able to do this installation yourself.

If I can provide further info, please post on this thread or PM me. Good luck with your installation!
Tom
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Old 08-02-2008, 06:09 PM   #2
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Re: Pop & Lock Installation

Caution on the directions: Look at the lower left hand corner for the date code... In the "Silver" set, the instructions are from "11-20-07"... The set that came with with the black is current, "6-08"...
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Old 08-02-2008, 06:16 PM   #3
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Re: Pop & Lock Installation

With either set of directions and the photo Tom pasted into this thread you should be able to do the install with no problem. It's pretty self explanatory.

Do be afraid of the instructions. If I could figure it out anyone can.
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Old 08-02-2008, 09:43 PM   #4
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Re: Pop & Lock Installation

Thanks for the helpful hints guys. This thread will really come in handy when I go to install mine. Yeah, I got the silver, and I noticed it has the "11-20-07" instructions and noticed it there are only 8 steps in the older instructions, as opposed to 10 in the new.

Thanks again guys.
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Old 08-03-2008, 07:10 AM   #5
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Re: Pop & Lock Installation

I would appreciate it if someone could take a picture of the mechanism when it is locked so I can see what it is doing when it locks. I'm also curious, can you move both handles when the lock is engaged?

Thanks
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Old 08-03-2008, 07:39 AM   #6
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Re: Pop & Lock Installation

Quote:
Originally Posted by ChrisM View Post
I would appreciate it if someone could take a picture of the mechanism when it is locked so I can see what it is doing when it locks. I'm also curious, can you move both handles when the lock is engaged?

Thanks
The P&L jams the handle mechanisms, Chris. The handles move slightly, up to the point where they contact the jam.
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Old 08-03-2008, 10:43 AM   #7
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Re: Pop & Lock Installation

Just finished... some of my observations and pics.... The lock is more for peace of mind... It should keep out the hitch hikers...

I used some gorilla glue to lock down the front half of the tumbler assembly to the back half. I wanted to make sure that if some wants to break in they can take the whole tumbler assembly and not just the front half; leaving the main shaft still attached to the locking mechanism and operational with some pliers.
Quote:
Originally Posted by Tcape View Post

3. In step #2, be sure you read the part about exchanging the bolts holding the bracket. Be sure to note that you can exchange the bolts you take out with the bolts you'll also take out in step #6. This is clearly covered in the instructions, but I almost overlooked it. If you don't exchange the bolts, the washers on the ones you initially take out won't let the bolts fit when the new bracket is installed.... No need for mine. All bolts are identaical... all contained the washer and locking washer... Fit without any issues.

5. Biggest problem I had was re-installing the tailgate cap. Took me almost 30 minutes to get the d*mn thing back on right!! In fact, that took longer than installing the lock. Be sure to look at how the plastic cap is made, and how it fits on the white clips. It has to be positioned just to the right of the clips...so the openings in the cap fit over the clips, then it slides to the left to lock into the clips.

I lined the tailgate cap up with the tailgate down. Position the screw holes of the cap just right of the holes on tailgate backing... The cap then slides right onto the tailgate.
You may need to push your hip against the middle of the cap to make sure it doesn't bow in the middle....
If anyone has any additional tips for re-installing the tailgate cap, I'm sure they'd be appreciated. I was unprepared for how big a hassle that was. At least for me.

I had to turn the driverís side inside clip 90 degrees as it would not catch but would come out and wedge in, making the cap not completely fit. I also did not use a rubber mallet to take it off, just used muscles and my weight..... ... I also did not require a rubber mallet to put the cap back on. It slides with a bit of effort. To make things even easier, donít clean the torx screw holes; use the dirt to realign the back panel.

Last edited by xridgelinex; 08-27-2009 at 09:35 AM.
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Old 08-03-2008, 11:08 AM   #8
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Re: Pop & Lock Installation

Quote:
Originally Posted by ChrisM View Post
I would appreciate it if someone could take a picture of the mechanism when it is locked so I can see what it is doing when it locks. I'm also curious, can you move both handles when the lock is engaged?

Thanks
Slightly.... Since the sideways handle operates via cable, I could see myself forgetting it is locked and overtime stretching the cable to the point of it not working...

From an engineering perspective .... I think the slight play is purposeful due to the tailgate mechanism being a conglomerate of metal and plastic. I would hate for the locking mechanism to be so tight with no handle movement to the point where temperature fluctuations would crack the plastic parts....
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Old 08-03-2008, 11:30 AM   #9
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Re: Pop & Lock Installation

Quote:
Originally Posted by xridgelinex View Post
I used some gorilla glue to lock down the front half of the tumbler assembly to the back half. I wanted to make sure that if some wants to break in they can take the whole tumbler assembly and not just the front half; leaving the main shaft still attached to the locking mechanism and operational with some pliers.
Assuming that it would break the way you describe.

The main shaft is plastic, my guess would be the screw securing the Crank Link to the Tumbler shaft would strip out under that kind of stress before the lock would split apart. This would leave nothing for the pliers to grab. I'm not into destructive testing, so I'll leave those assumptions up to you. I'm satisfied knowing this lock offers more security than the lock on my Tonneau.

I agree the lock is for piece of mind, as is every other lock I own. As I said on a previous post in another Thread, a properly placed crowbar will open a Tonneau in seconds. This lock offers an additional level of security and hassle to anyone trying to get into it. It wasn't designed to replace anything at Ft. Knox.

Last edited by Pizza Man; 08-03-2008 at 12:20 PM.
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Old 08-03-2008, 03:39 PM   #10
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Re: Pop & Lock Installation

PIZZA MAN,

I'm sorry to ask, I'm just wondering if I can still join the group buy for pop & lock? I posted on your ordering thread and asked the same question. Please let me know and the method of payment. I want a black color.

Thank you and appreciate your reply.
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