Installing a D and C Extreme FlipSert
(So easy a 3 year old could do it! ~ almost)

INTRODUCTION

If you're reading this then you've come to the realization that the SOA you just did on your rig is seriously messing up your steering. You've also realized that when you flex out your rig, your passenger side spring is going to hit and bend your tie rod. And if you actually go wheeling with it the way it is now, you may end up with this!

There are very few things you can do in this predicament (most of them require you limping home). However, D and C Extreme now offers you a good viable answer to this problem. And it's called a "FlipSert". A FlipSert is a small bushing that is built to simply replace the standard knuckle's tapered hole. It allows you to literally flip the tapered area upside down so that your DragLink will mount from the bottom of the knuckle. This extra space allows you enough room to completely flex your suspension without worry of destroying your new custom DragLink.

Sound complex? Don't worry its not. In fact, it's so easy to do, a 3 year old can do it. Want proof? Ok, meet Matthew ~ He's my 3-year-old son. And although "Daddy" is going to help him ~ he is going to do the complete install of a FlipSert into a Scout II steering knuckle.

Note: This whole process can be done in the vehicle but we don't recommend it because you may have some problems keeping the drill in your hands. You see, if you hint of wobbling, the drill bit may jam in the hole and bend the bit, smash your fingers against the springs (or some other hard object) or completely tear the drill out of your hands. We recommend that you use a Drill Press and securely clamp the knuckle to its table. This way will require you to completely disassemble the passenger-side of the front axle. This is the way that we'll use in these installation instructions.

Step 1. Get the knuckle (about 30 minutes)

Completely disassemble the passenger-side of your front axle. This requires you to:

• Remove the lockouts and hub assembly.
• Remove the caliper (Don't let it hang on the brake line).
• Remove the hub assembly (keep track of all c-clips, nuts, washers, etc).
• Remove the spindle (including dust cover and caliper bracket).
• Remove the nuts on the upper and lower ball joints.
• Remove the steering knuckle.

Step 2. Drill out tapered hole (less than 5 minutes)

This step is quick. Chuck a ¾" Metal bit into the press. Simply secure the knuckle to the Drill Press's table using C-clamp or similar type device. The knuckle material is a little softer (due to the alloy, they are made to bend not shatter) so make sure you drill the ¾" hole through slowly. It helps to drill from the bottom side as to not bind the drill bit in the tapered hole.

Step 3. Install the FlipSert (15 minutes)

D and C suggests that you secure the FlipSert into the knuckle by inserting it from the bottom and then welding it into place from the top (being careful not to get 'spatter' on the inner cone area of the FlipSert. However, FlipSerts can be held in place using many different methods (such as epoxy, "LiquidMetal", welding, press-fit, etc.).

For demonstration purposes, we will simulate an installation using an epoxy that is compatible with metal.

1. Clean both the knuckle, the ¾" hole, and the FlipSert with an appropriate cleaner.	2. Thoroughly mix the epoxy resin as directed on its container
3. Apply epoxy to the insides of the ¾" hole (in knuckle) and to the outer part of the flipsert (DO NOT APPLY TO MUCH - COAT LIGHTY)	4. Insert FlipSert front the bottom of the knuckle ~ push until it's fully inserted.
5. Wipe all excess epoxy away cleanly - DO NOT get any on the inner 'cone surface'	6. Let cure.

Step 4. Check Fitment (1 minute)

This is perhaps the easiest part of the install. Simply install a stock tie-rod end and admire!

Step 5. Install knuckle (about 30 minutes)

You're pretty much done, so put back together your axle and drive away.