INSTALLATIONAluminum FlooringSystem

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Note: Steps described in this installation guide are mandatory to follow and should be done as described except as noted.

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UNBOX PEEL & STICK

ATTACH

ATTACH THE LIFTING JIG

INSERT & DROPLOAD DRILL & BOLTPREP, PRIME AND GLUE : TRIM & CLEAN

ALFO: Assembly process overview

SNAP

CONNECT LIFT & TILT

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To comply with manufacturers’ warranties and ensure proper adhesion of the aluminum extrusions to

the van floor, please refer to instructions mentioned in Sika Guidelines.

All of the following steps should be performed at temperatures between 59°F (15°C) and 77°F

(25°C. Do not apply below 50°F (10°C) or above 95°F (35°C).

Seal all the holes on van floor with silver duct tapes to avoid the dirt and water inside the BIW

before the installing ALFO floor

Note: For the use of manual foot with ALFO seating systems or assembly aids, use only M10 grade 8 bolts

Note: Steps described in this installation guide are mandatory to follow and should be done as described except as noted.

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Hangers

Forklift Connection

Chains

Linear bearings

Trimming Template for Gerfloor WB148, WB130

Locator FrontLocator Pass Door

Locator Rear RH

Locator Rear LH

Beam Slider

LIFTING JIG & HANGER

Trimming Template for Gerfloor

Trimming Templates for Gerfloor

Assembly locators

ALFO ASSEMBLY AIDS

Hangers

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Basic Hand Tools

Sikaflex 255 FCBlack

SikaFlex Applicator Gun Sika 206 Primer

Rubbing Alcohol Cleaning Rags Mallet

Drill Forklift(For use with ALFO Lifting Jig Kit)

3/8” x 18” Drill Bit

These items are not included in the kit.

R e q u i r e d To o l s

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L-Track Covers

Nylon Lock Nuts & Washers

Ford Transit Body

Sika Flex 255 (Black)

Floor Spacers

Underbody Reinforcement Plates

Non-Skid Rubber Flooring

MountingBolts

Rectangle PlankWashers Plates

ALFO Panels

E x p l o d e d V i e w

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As the kit is unpacked from the shipping crate, the

aluminum panels should be inspected to ensure they

have not been damaged in shipping and handling and

ensure that all components on the shipping bill of

materialsare received.

THE INSTALLATION SHOULDNOT PROCEED IF THERE IS ANY

DAMAGEOR SHORTAGE.

Shipping Crate

Part Image Part Description WB130 WB148 WB148 EL DRW

ALFO Aluminum Panels 12 12 13

3/8”-16 Thread Size, 12” Long 2 2 2

3/8”-16 Thread Size, 7” Long 2 2 4

3/8”-16 Thread Size, 5.5” Long 1 1 1

3/8”-16 Thread Size, 2.5” Long 7 7 8

3/8” Screw Size - 1” OD Washer 12 12 15

3/8”-16 Lock Nylon Locknuts 12 12 15

Panel Washer Plates 12 12 15

Underbody Reinforcement Plates 12 12 15

Floor Spacers 5 5 6

Foam Sides 2 3 3

Foam Corners 3 3 0

ALFO STANDARD KIT SHIPPING BILL OF MATERIALS

STEP 1 : UNBOXING THE CRATES

This Panel Washer plates are only for old stock, new stock of ALFO kits will be provided with regular washers.

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Driver SideMale Side - Keep on left

Passenger SideFemale Side - Keep on Right

Driver Side

Passenger Side

ALFO Panel Label

Safety Information

Panel #

Install Direction

Prepare the work surface near the van to minimize labor, handling and the chance of damaging components of the ALFO flooring system. The

ALFO kit should be opened on a raised surface (table) that fully supports the length of the extrusions which is free of dust and debris. The

panels should be laid out next to each other on the table in the layout in which they will be installed in the van. (see next page for layouts) A

label on each panel (shown above) will have an arrow pointing to what will be the front of the van. The snap fit feature on the panels should be

oriented such that when looking from the rear to the front of the van, the female side is on the passenger side and the male side is on the

driver side.

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C20

C20

C20

C20

C20C20

C20C20

C10

C10

C10

C10

C10

C10

C10

C10R13A

R13AR23AC30

C30

C30C30

C30C30

C30C31A

P10D10

P20D20

P20D20

C11A

FRON

T

C21A

C33A

R21

W B 1 3 0 W B 1 4 8 W B 1 4 8 E L D R W

P a n e l P a r t N u m b e r s ( L a y o u t )

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The ALFO floor snapping tabs are designed for dry fitting and

final install. The panels you have received are currently set up

for dry fitting. The panels can easily side together and apart

when needed. This feature makes it very easy to install panels

when dry-fitting your ALFO floor. Once the dry fit is

completed, gently bend the top and bottom tabs in three

locations along the panel length. This slight bend will allow

the panels to snap together to aid in aligning and installing

the ALFO floor.

Snapping tab

This step is not mandatory

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SNAP: Restrict a panel on the passenger side and fit the adjacent panel male side against it. Using an impactor to avoid damage to the snap-

fit tab, tap with a mallet to insert the male side into the female side of the two panels along their entire lengths. PARETO IS NOT

RESPONSIBLE FOR DAMAGES TO THE SNAP-FIT TABS IF EITHER AN IMPACTOR IS NOT USED, OR IF EXCESSIVE FORCE IS

USED. Repeat this process until all aluminum panels are snapped together in the proper layout. Use the mallet to align the ends of the at

the rear end.

S N A P T O G E T H E R

STEP 2 : SNAP

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FRONT

W B 1 4 8 K i t

W B 1 3 0 K i t

W B 1 4 8 EL D R W K i t

P20

P20

P10

P- P a n e l A l i g n m e n t

TBD (38.5”- 40”)PASS SIDE

TBD (38.5”- 40”)

TBD (38.5”- 40”)

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C h e c k P a n e l A l i g n m e n t

Hanger alignment pin

with panel holes

L Track Hole

Once panels are arranged in the correct pattern, use the lifting hanger to check

alignment. If the hanger does not drop into the holes on the panels and sit flush to

panels, make adjustment to panels and recheck. Once the hanger drops into

holes on all panels and sits flush, the alignment is correct.

Please note this action can can be completed on table before ALFO floor is installed.

Drop into Holes

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PEEL & STICK: This step is optional, depending on whether you will use a floor covering. Use a rag to wipe the top surface of the assembled

panels with isopropyl (rubbing) alcohol. Starting at one end, place a roll of Gerfloor (or similar) rubber precut to width in the floor groove between

the integral L-tracks. Peel back the plastic covering and press the rubber strip into the groove as you move down the panel to make the covering

stick and keep it smooth along the length of the groove. At the end, trim to fit. (Please see next page for addition information)

A L C O H O L AND R U B B E R F L O O R

Do not start Gerflor installation until holes are aligned using hanger.

STEP 3 :PEEL & STICK This step is not mandatory

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W B 1 3 0 K i t

W B 1 4 8 EL DR W Ki t

Install full length Gerfloor pieces on panels shown.

Remaining Gerflor will be installed at a later time.

Please note this action can can be completed on table before ALFO

floor is installed.

I n s t a l l ( G e r f l o o r ) R u b b e r F l o o r i n g

T r im C33A & C31A( DRW ONL Y )

W B 1 1 4 8K i tWB148 Kit

Do not start Gerflor installation until holes are aligned using hanger.

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H a n g e r A d j u s t m e n t

If you are using only Ford interior, then cut the rear hanger at the

notch as shown

Attach the hanger to the floor using the bolts and manual foot.

Ensure that the hanger alignment pin can go into the L Track

holes. Use mallet to align the panels if needed

Cross Section View

Bolt

Hanger

Lifting Foot

Panel

Assembled View

Full Length Hanger

Adjusted Hanger

S T E P 4 : A s s e m b l e a n d I n s t a l l L i f t i n g B a r s

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57”

57” 57”

130WB 148WB

148WB-EL

Approximate location of lifting jig on the floor

17This step is not mandatory

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57”

12”

Lift the floor & prep for cleaning

Attach the Lifting Jig: Install lifting jig on to forklift. Next, drive forklift

and lifting jig over table (see bottom right mage) Once chains are aligned

with lifting jig, attach chains to the hangers using the supplied

carabiners. If needed the chains should be adjusted so that when the

jig is lifted by the fork truck, the floor will hang about 2.5’ below lifting jig.

Leave floor on table and move onto the next step.

Locking Slider

18S T E P 5 : P R E P T H E L I F T I N G J I G

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LIFT, INSERT & LOWER. Being careful not to contact the sides of the

van interior, the ALFO is inserted into the rear of the van and lowered

on the van floor. This process is just for the dry fit of floor for first time

installers to check with Assembly locators ( shown in next slide)

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Rear LH locator Rear RH locator Side RH locator Front locator

Adjust the sheet metal bracket on the aluminum locator block to ensure the right position during first time dry fit . After the dry fit, remove the ALFO floor to prep for the final installation. This is just a dry fit for first time installation.

As s e m b l y L o c a t o r s ( O n e T i m e S t e p w i t h D RY F I T )

This step is not mandatory but is highly recommended to avoid misalignment.

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I n d i c a t e s w h e r e to a p p l y P r i m e r

S T E P 6 : A P P LY S I K A P R I M E R A N D S I K A F L E X

Note : Thick black boxes indicates the location for Alfo Spacer

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I n d i c a t e s w h e r e to p l a c e S i k a f l e x 255 FC.

A p p l y S i k a f l e x 2 5 5 F C

Sikaflex 255FC Black Sikaflex ApplicatorGun

W h e n a p p l y i n g S i k a f l e x t o f l o o r

p a n e l s a 3 / 8 ” b e a d o f g l u e i s

r e q u i r e d . T o a c h i e v e t h e d e s i r e d

b e a d c u t ¼ ” s l a s h c u t o f f

a p p l i c a t o r t i p . Applicator Tip

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Rear LH locator Rear RH locatorSide RH locator

Front locator

Drop the locator blocks into the existing holes of the Ford transit body and adjust them to define the floor location.

Rear

Side Step

Assembly Locator

This step is not mandatory

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LIFT, INSERT & LOWER. Being careful not to contact the sides of the

van interior, the ALFO is inserted into the rear of the van and lowered

into place on top of the adhesive. The jig is disconnected from the lifting

hangers and removed on the forklift. Any final adjustments to the

positioning of the extrusions are now made. Installation will be easier

with an extra person to look for correct positioning and avoiding any

contact to trims.

S T E P 7 : LIFT, INSERT & LOWER

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APPLY WEIGHT. Once floor has been put and place and the forklift and lifting jig have been removed from Transit, walk on the floor to applypressure to the floor to help the Sika flex take hold to the aluminum panels before drilling the bolts through . Next place ten sandbags orequivalent to 600 lbs. on ALFO in the place indicated above for at least 6-8 hours.

Apply weight towards front of ALFO floor.

All bolting should be completed within 1 hour of gluing the floor

S T E P 8 : A P P LY W E I G H T

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Weight must be left in place for at least 6-8 hours. If you wish to remove the weight before this time, or not use the weight, you must

install drilling screws at the front, as illustrated.

( O p t i o n a l S t e p )

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DRILL & BOLT.Drill holes for 3/8” bolts and then insert the bolts through the drilled holes in the panels and the OEMvan floor at the back of the

van and in front of wheel well. (SEE NEXT PAGE FOR BOLT HOLE LOCATIONS) The ALFO is fastened under the OEM floor using the provided black

oxide alloy steel bolts and washers, rectangular washers, underbody reinforcement plates, washers and lock nuts. Tightening torque to bolt

the nut is 45 lb./ft^3.

I m a g e of p r e d r i l l e d h o l e in e x t r u s i o n

Drill3/8” x 18” Drill Bit

All bolting should be completed within 1 hour of gluing the floor

27S T E P 9 : D R I L L & B O LT

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Bolt12”

Bolt5.5”

Bolt2.5”

Bolt2.5”

Bolt7”

Bolt7”

Bolt2.5”

Bolt2.5”

Bolt2.5”

Bolt2.5”

Bolt12”

Bolt2.5”

Bolt12”

Bolt5.5”

Bolt2.5”

Bolt2.5”

Bolt2.5”

Bolt2.5”

Bolt2.5”

Bolt2.5”

Bolt12”

Bolt2.5”

Bolt2.5”

Bolt7”

Bolt7” Bolt 7”Bolt

7”

B o l t L o c a t i o n s

WB130, WB148 WB148 EL DRW

All bolting should be completed within 1 hour of gluing the floor

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L O C AT I O N O F H O L E S T O B E U S E D F O R B O LT I N G P U R P O S E f o r F o r d t r a n s i t .

C30

FRONT

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L O C AT I O N O F H O L E S T O B E U S E D F O R B O LT I N G P U R P O S E f o r F o r d T r a n s i t

C21A

D20

FRONT

C20

P20 R13A

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Underbody Reinforcement Plates

Nylon Lock Nuts & Washers

ALFO Panels

Washers ( 2 Circular or 1 rectangular)

Mounting Bolts

2 . 5 ” & 5 . 5 ” B o l t A L F O F l o o r F a s t e n i n g P r o c e s s ( T h r o u g h F l o o r P a n e l s ) 31

Bottom View

Section View

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7 ” B o l t A L F O F l o o r F a s t e n i n g P r o c e s s ( F r o n t o f W h e e l W e l l )

Section View

Bottom View

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1 2 ” B o l t A L F O F l o o r F a s t e n i n g P r o c e s s ( F r a m e R a i l /B u m p e r B e a m )

To install a reinforcement plate, washer and nut on to install 12”

bolts. The rear bumper bracket must be lowered to access the

bottom of the 12” bolt. To lower rear bumper bracket, first remove

(6) bolts indicated by blue arrows

Next , slowly rotate bracket low enough to access bottom of

12” bolt. Next place (1) underbody reinforcement plate, 3/8”

washer and 3/8” nut on to 12” bolt. Tighten to 45lbs (Please

not, only unbolt and lower one side at a time. Doing so

maintains position of rear bumper in vehicle. If both brackets

are removed rear bumper will fall.

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Finish Foam on all sidesAnd apply foam corners

Apply a thin bead of glueAnd apply the foam sticks

Use EPP foam of ¾” to fill the gaps (Included in kit)

S T E P 1 0 : F i t a n d F i n i s h w i t h F o a m a n d G e r f l o o r

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Cutting template T02 for WB130 & WB148 only

14.25”

Align the template on the center of

Gerfloor

Slot to mark cut line for A/C Blower

TP02

TP02

TP01

TP03

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BEFORE USE OF SEATS ATTACHED TO THE ALFO, THE ADHESIVE MUST BE ALLOWED TO CURE FOR 6-8 HOURS

FOLLOWED BY INSTALLATION OF SEATS.

WHEELCHAIR LIFT CAN BE INSTALLED AS SOON AS FLOOR IS GLUED

ANY FAILURE TO FOLLOW THESE INSTALLATION INSTRUCTIONS IN ANY MATERIAL RESPECT IS AT VAN CONVERTER’S

OWN RISK, AND VOIDS ALL WARRANTIES AS TO THE INSTALLATION AND PERFORMANCE OF THE ALFO ALUMINUM

FLOORING SYSTEM.

PARETO ALUMINUM SYSTEMS, LLC

660 AJAX DRIVE, MADISON HEIGHTS, MI 48071

Revision Date Sept 16, 2020

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