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C-Series Tray and Divider Installation Suggestions

General instructions for installing dividers or trays in EWI road trunks:

Installing the dividers or tray support rails are a do-it-yourself project.  We don’t offer specific instruction because of personal choice of placement of the dividers or tray in the case, so the following is meant as general guidelines:


Dividers:  It’s a fairly straight-forward process of deciding where you’d like the dividers, mark and drill the holes for the machine screws and install:

1)    Position the divider where you’d like it and mark the holes you’ll be drilling.  Use a tape measure to check that your divider position is square with the world. 
2)    Mark the mounting holes to use one 5mm machine screw per each of the divider’s 4 brackets, even though there’s 3 holes in each of those brackets, just pick which hole you’d prefer to use.  Use a good Sharpie or similar to mark the locations of where to drill the holes.  You’ll be marking where to drill the holes on the foam inside the case.
3)    Drill the holes for the 5mm machine screws using a 13/64” drill bit.  You’ll be drilling from the inside to the outside.
4)    Install the divider using the 4ea. 5mm machine screws.  Use an 8mm nut driver or similar to hold the nuts, and a #2 Phillips screw driver to hold the heads of the 5mm machine screws.  Only tighten the nuts “reasonably snug”… the nuts do not need to be tightened down hard because they are lock nuts.



Tray support rails:

1)    Decide how high you want the rails in the trunk.  On all C-Series road trunks the minimum mounting height of the tray rail is 4 ½” down from the top of the foam that lines the sides of the lower portion of the case.  This is the minimum height needed for the lid to close on the tray.  The rail can be mounted lower if more room is needed for gear that may stick up above the tray.   Position the rails so the holes for the 5mm machine screws are below the ledge of the rails where the tray will ride, because if you position the rails (and drill the holes) so the machine screws install above the ledge the nuts will obstruct the tray from sitting on the rails.
2)    Carefully mark the locations of the mounting holes for each tray support rail, drill the holes using a 13/64” bit and install the tray support rails using the 5mm machine screws and nuts.  You may find it easier to lay-out the locations for drilling the mounting screw holes on the outside of the case so you can drill from the outside to the inside, which can be done by measuring down from the top fold edge of the lid-mate extrusion relatively the same as you’d measure on the inside, then position the tray support rail and mark through the mounting holes on the support rail to the laminate. 
3)    Use an 8mm nut driver or similar to hold the nuts, and a #2 Phillips screw driver to hold the heads of the 5mm machine screws.  Only tighten the nuts “reasonably snug”… the nuts do not need to be tightened down hard because they are lock nuts.