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INSTALLATIONAluminum FlooringSystem
TM
Note: Steps described in this installation guide are mandatory to follow and should be done as described except as noted.
TM
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
TM
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.
TM
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
TM
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
TM
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.
TM
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 )
TM
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
TM
57”
57” 57”
130WB 148WB
148WB-EL
Approximate location of lifting jig on the floor
17This step is not mandatory
TM
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)
19
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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.
TM
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
TM
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
TM
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 )
26
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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
28
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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
29
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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
30
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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.
33
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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
TM
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
35
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36
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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
37