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Malone XtraLight LowMax Trailer Assembly

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Assembly of the Malone XtraLight LowMax Trailer


Adam: What's going on, everybody Adam here with etrailer. Today, we're going to be taking a look at the Malone XtraLight LowMax Kayak Trailer. So if you're like me, and you don't got a truck and you have a lot of kayaks and you want to go yakin', well, this is going to be able to get four kayaks up and secure down. So where you can have just a designated trailer to take your kayaks wherever you want, leave them, load it up, or even just break it down and keep it in your shed or something like that. Super easy to store, but then you have a trailer designated for this activity. So whenever you want to go, it's ready to rip.To begin the installation, I highly suggest taking all the parts and laying them out as neatly as you can, kind of go over all the different sections of parts that we have.

One, we have pretty much just the main frame and the tongue right here, the bigger stuff. We got the load bars in the back. Of course, we've got the tires and our fenders and the actual. We've got the leaf springs, and then we're going to have all of the lighting components. And then of course we have all of the hardware.I highly suggest having all this laid out in one place and then right next to it, where we can assemble and have plenty of room somewhere relatively close.

So I'm going to be having all the parts here, slowly picking from this big old pile of stuff and we're going to see a trailer develop right over there slowly but surely.So I have the frame of the trailer pretty much mocked up the way it's supposed to be. One thing we need to take into account is which bars we're using. So the front bar is here. We're going to have two that are going to be pretty much symmetrical. We're going to have the open end facing towards the back of our trailer.

And then for the sides here, there's a couple of holes. We want to make sure that they line up in they're pointing the right direction. So we have these three down here. Kind of imagine it as a little arrow. You want that arrow to be facing up.Then back here, we had these four little holes and that's going to be towards the backend of the trailer.

And then the farthest bar here has the Malone on it, and that is going to be facing out. So you want them Malone sicker to be facing out. So this one is going to be opposite of the other two up there. We're going to take our little hardware and I just go ahead and kind of just put them in just so it doesn't fall down whenever we're getting it all assembled and then we're going to take our nylon lock nuts and just hand tighten them for now.Now that we got that done, all we got to do is just flip the trailer over. We are going to just have it like this for a couple more steps of the installation process. It just makes it a lot easier to get some of those components installed on the trailer. Now, we're going to go ahead and assemble the tongue. We're going to have two different pieces. One is going to have a nice little sticker on it.That one is going to be where the coupler is going to go and then there's going to be a bear one. But then you need to take into account the holes. We have two holes drilled in the center of this one and they are going to align with the two holes drilled in the center of this one.So don't get that confused because with this one they're not in the center. That's going to be for our coupler. So put that to the side and put it up right side up or actually upside down since we have the whole entire trailer completely upside down. So put that to the side. So pretty much all we need to do, make sure the two holes are going to be facing out away from the trailer and then put it into place. We're going to have a long bolt here, long half inch bolt with a washer. And then we're going to have a short one for the one up here.So pretty much just put them into place. I like doing the farther one first, just to make sure this is going to sit up like this and then we'll actually go ahead and completely tighten these down. Just go ahead and put these in place. And then the small one we're going to actually put on the inside of the tube, like that lined up with the hole like that and then put a hard nut on.So I'm going to get it nice and tight here. And you can go ahead and take a 19-millimeter socket and wrench to tighten everything up. And our longer bolt is just going to go straight through the top, through all the holes, and then we'll put the lock on it.Next thing we need to do is connect the very end of our trailer tongue to the part that we just secured down. To do that, all we got to do is take our two brackets. They're completely symmetrical. Whether it's just like this or like this, so you don't have to worry about putting them on wrong. I have found it easiest to just put it up on the first one. We're going to take our longer screws here with a washer, line up the holes like that and push them through the other side.Then we're going to have nylon lock nuts to secure them down. And we can go ahead and tighten these completely, just because it is a tongue, and there's no reason for us to just keep hand tight.Now, we'll just go ahead and take the rest of our tongue. Make sure that the Malone is going to be upside down because the whole trailer is upside down. Slide it in there and then we're going to take our little pins, put them into place and they do come with little pins to go through the little holes on one side. Once we have all that down, we want to go ahead and maybe tighten these up a little bit more just to make sure it's nice and secure.Now, we're going to add a little bit of support to the tongue of the trailer. We're going to take two brackets like this. I already kind of have this one mocked up, but notice one thing. This is not in the center. So it is not a symmetrical bar. We want to find the section where the middle little hole is the closest to this hole and that is what is going to go right there. It's going to align up with this hole and this hole here and pretty much you're just going to put it up on top of there, put a bolt through.But on the other one, we are going to have a little washer, because it's a little bit bigger hole and we're going to use the washer to that one. But the same nylon lock nuts for both of them.To secure these down over here, all we got to do is take our two flat plates. We're going to take the first one and just put those long bolts through. And then we're going to go ahead and fit them through the holes, just like that.Then we're going to take the other backing plate right here. Put it on top. And remember, this is upside down right now. So I usually just like to have the more side that's going to have more sticking out on the bottom. So you won't see as much. And then of course, nylon lock nut and then 9/16 socket and wrench, tighten them up.I like to go from one side to the other, make sure it's evenly tightened down. I Highly suggest doing that. So what I'm going to do is actually go from this bolt to this bolt, to these two and to the other over there and kind of just check each one, go back and forth just to make sure everything's going to be nice and tight and not really tweaked or anything like that. So I highly suggest doing that. And again, just with the same exact socket and wrenches before.So I went ahead and ran the wire after I put the tongue together. Probably not the easiest way to do it. Honestly, if I was you, before you start putting the tongue together kind of just run this wire through there first because then you can take the pipes up and just kind of dropped the stuff down there. I got it done, but if you want to go the easier route, just run that wire before we put this tongue together.So now let's prepare for the actual. More specifically the leaf springs. They're going to need to be mounted somewhere. So we have our brackets. We need to make sure that we put the right brackets in the right spot because we have two different kinds. One is going to have a little hole through it and one is just going to hook onto that leaf spring. So the one that has a hole through it is going to go up towards the coupler of our trailer.So be sure to do that. Hold the line up perfectly like that and of course the other one just goes in the other spot. And then we're just going to take these little bolts, put them down through and then we'll have a nylon lock nut to put on the bottom. Once we get those all in place, tighten them on down.Now, we're going to go ahead and prepare the axle. So first things first. Grab the axle. It's pretty obvious to know which one's which. So we're going to have one side that's going to have holes and the other side won't. So we want to have the hole facing up just for the installation of our leaf spring. We're going to go ahead and just line it up the best we can and then take our U bolts and go ahead, slide these around that bar and end of this plate.We want to make sure it lines up because there's going to be a little divot right there. We're going to fit into that center hole. And then obviously just put the U bolt on the other side. We're going to take the nylon lock nuts that came with it and screw those on, get them hand tight for now because to get these leaf springs to sit into place into the brackets we installed earlier, we're going to need to have a little bit of wiggle room.So just thread them on by hand right now. Now, that we have the bolts hand tight, what we want to do is we want to make this side look like this side. So as you can see, we have them to where the nuts are just hitting the plate, but it's still got some wiggle room. That's what we want. Do not tighten it any more than this right here. So I'm going to go ahead and do that here and move on.So now we'll go ahead and take our axle. And what we're going to do is take the side of our springs that doesn't have a little islet hole, and we're going to slide those into this brackets on the back. Just like that. This is another reason why you want to make sure you don't tighten these down because it's nice to be able to wiggle them into place.So now we're going to have our axle bolts. They're not going to be threaded all the way through, okay And I'll go ahead slide that in, hand-tighten those on both sides. Then what we want to do before we fully tighten these, this bracket is still a little loose. We want to go ahead and tighten these four up here and then we can go ahead and tighten down these eight all the way and then we can go ahead and tighten these down.So go ahead and do all that. And then we're pretty much good. When we are tightening down these brackets, we do not want to over-tighten them because we need to have a little bit of wiggle room in here so that spring can actually go ahead and travel. If you want to know if it's too tight or not, just make sure that this bracket doesn't bend inward and if it's not, and it's still at least to the nylon part of that nut, you are A okay.Time to put on the shoes. So all we got to do is make sure that you had the tire stem facing out. And also I have found it a little bit easier if you put something underneath the trailer just to get the hub elevated a little bit more so you don't really have to try to keep the trailer up and then get this thing on. I just put a little tiny toolbox thing on underneath of it. So now I can just go like that and there won't be any pressure on it. So what we want to do now is take our lug nuts and we want the tapered portion right here to go on to the stud.So get those on there, get them hand tight. And I do suggest putting them on in a star formation, so we have five. So I started on the right and now I want to go cross, go down here. You should to really push the tire up against the hub so we can get it seated nicely. So we really don't have a whole lot more tightening to do once we flip the trailer over.Now, we can go ahead and flip the trailer over. Always keep your back straight and lift with your legs, okay A lot easier on you. Go ahead. It's actually really light. Not near as hard as I thought it was going to be and check it out. Starting to look like a trailer. Now that we have it upright, you might as well just go through and tighten all the bolts that we just hand-tightened before. If you haven't already done that, go ahead and do that now.Now it's time to torque all of our lug nuts down. We want at least 75 foot pounds, but no more than 85 foot pounds. So grab yourself a torque wrench and torque them down. Again, I do the same exact star pattern.There we go. And continue to do that for the rest of the four here and the other five over there.Now, let's go ahead and put our light brackets on. So they are the same exact bracket. It doesn't matter which one you put on what side. So grab one of them. And then we're going to take little carrier bolts here and push them on through.We are going to have nylon lock nuts on the back end of them. And we can go ahead and actually tighten those down. We can do the same exact thing for the other side.So on our passenger side of our trailer, I'm going to use the light that doesn't have our other function down here. So that's going to be for a license plate. We're going to put that on that side. So we are going to have little nuts that are going to go right here. They're already going to be on there. Just take them off real quick. And we want to make sure that this side marker lights going to be facing out on the side of course. Then you can just go ahead and place this down and tighten them up.Next thing we need to do is go ahead and put our side marker lights on. So we have her three little holes there. We're going to put the threaded stud in the middle hole, but it lines up perfectly to put our wires through the other ones. So put it one at a time. They're not going to fit at the same time. Don't even try it. I did. It didn't work. So get those through like that. Perfect. And then we're going to have a little nut. It's going to be on them. Take that off, put it where I just did and put it on. We can do the same exact thing for the other side.Next, we need to run power to all the lights we just hooked up. How we're going to do that, well, we have a little wiring harness here. It splits into two and then it splits into two again. So if you notice on our tail lights, we have different color schemes. So on our passenger side, we are going to have the green one. So that is what's going to go all the way back. But then we're going to have to power our sidelights and that is just the white and the brown. We're going to have the same white and the brown on the other side for the running lights.It's not really side-specific, but the other side is going to have yellow and that's going to be for our driver's side. So wrap those the way you can, whatever fits best for you. Really just make it yours, whatever's the best and hook them all up.Now, that all of our lights have connections they're made. Now, we can go ahead and make it pretty. We have a bunch of clips that come with it. They're relatively hard to kind of get on there, which is good. They're not going to come off, but just route all these wires up and around where you think they'll stay out of trouble.You kind of put them on there. They're not going anywhere. And then you kind of just slide that wire up in there, make it look pretty and protect them too. Now that the wiring is all taken care of. Now, we can go ahead and put our bumpers on. So what we want to do is a little skinnier part. You put a little washer in there, take the long little bolt here, push it through. It should stick out or out about there. Small little nylon lock nut and we can go ahead and grab, put it in this last little hole here on the end, a little bumper just in case you back up and you're a little too close. So it's going to be the same thing on the other side and you can just go ahead and tighten it down and those are good.Next thing on our list is to assemble the fenders. So pretty much, we're going to take these brackets right here and we're going to line them up with the holes, so the longer section of this bracket is what we'll line up with the holes here. So what we're going to do is take the bracket and we're going to take our little flat nut right here and we're going to put it through there and then nylon lock on the other end. We're going to be doing two per bracket and two brackets per fender.Now, we just need a flat head for one side and our socket for the other and tighten those up. Then we want to go ahead and take the holes right here. And they're going to line up with these two holes right here. I found it easiest just to put the bolts in place. Slide them in there like that and just prop it up with your knee. We will be putting washers on these. Put them nice and hand-tight, and then we can go through here and tighten it up.After that, what we're going to do is assemble our coupler. First things first, let's go ahead and take our safety chains and our bracket that looks like this. So what we're going to do is there's a little notch on here. It's going to fit in and we're going to have our bolt like this. What we're going to do is go through the ends of our safety chains, go through this, just like that and fit it into the two holes.We'll take our nylon lock nut. So when you're tightening this down, getting most of the threads taken care of, but then once the bracket started getting really close to the trailer, we want to make sure that we get this back section of the bracket up and into that hole. So I tightened it a little too much. So just be a little mindful, but there's quite a bit of threads we got to go through.Now, it's time for the coupler, put it on right there. And I have some big old bolts. What we want to do is depending on what side you rather have the handle on, I'm going to do it on the side, line all that up, put that through. And again, we will be using two nylon lock nuts on the end and I'm going to be using three quarter inch wrench and socket to get these guys tightened down. One thing to note, we do not want to over-tighten this. We don't really want us squish that tongue and deform it much. So be mindful of that.Whenever you're tighten this stuff down, go back and forth to make sure it's nice and even. Now, what we want to do is take our shorter posts here. They're a little bit thicker than our load bars and we're going to make it look like this one. So we have a hole up top and we're going to have two holes down here. That's where our U bolts are going to go, but that's where we want to put the cath. So just put it in there. You will need a hammer. It's kind of hard to do it like that, but I guess you could do it if you really wanted to. Just put those in right now to repair for the load bars.What we want to do is take these and put them on all four of the corners. Kind of just take the U bolt, line up the holes, slide it in there, take our nylon lock nuts and screw those on. I am going to be using a 9/16 inch socket, but the one I have is a little short. These U bolts are rather long, so you will need a deep well socket.One thing I like to do with these is to go back and forth. I want to make sure that U bolt is nice and even. And of course just constantly hold this bar up into that corner.Next step to prepare for the low bars is our little brackets. So you're going to slide this on, take a little bolt here, slide that through. And of course, end it off with a nice nylon lock nut. We're not going to tighten these down yet, but I'm going to put all these on for the rest and we're going to tighten down once we have all the low bars ready and set into place.Now, it's time to load up our load bars. I just slid them into little slots here just to keep them stationary. It's a little bit easier to put these tie-downs on. So what we're going to do with the tie-downs, we're going to have two different sides. One side is going to have a couple of little dots. That's going to go towards the bar and the other side is going to be nice and smooth.You want that to be outside So pretty much you just take a little bolt and a washer, put it in there, we'll have a nylon lock nut, and it is rather tricky to get this all sorted out. So just fit it in there, get it threaded in just like that. And then you can go ahead tighten it up. 9/16 inch ratchet and socket.Last thing to do just for the load bars to dress them all up is take the little caps and push them in there. You can probably get it with your hands. If you need a hammer, you can, but try to be as gentle as you can. Next thing, we're going to have a long bolt. We're going to lift this up on the bracket, stick that through so that bar is going to be above this bolt here. And now we can go ahead and do that for the remaining of them and then position them to where we want them and tighten everything down.Now it's time to put our yaks up and secure down. As you can see, I already got one done. It's pretty easy. I like how I don't have to worry about it scratching my kayaks. So if you have some that are painted or just really, really nice, you don't really have to worry about it scratching everything up. Straps are included and I really liked them and how easy it is to kind of time all down. What I do is just, I'm going to fish it through the top one because I'm going to use the bottom one for the others. And then we're going to just go down and we're going to wrap it around this bar on the other side.It might be easiest to get an extra set of hands, but you don't need it. Now, we want to make sure that this is going to be rotated in the right direction to where this little scuff preventer is going to be up and against the kayak. Let's take the rest of the strap, put it through that little piece just through here, start tying in and up.As you do it, try to make it to where this little buckle right here is going to be down towards the front, which is easier to get it untied and give her a good old tug. Honestly, just with one, it's super secure, but we are going to put two straps just the same exact thing on the back here. You can go ahead and put the excess strap wherever you see fit.Well, we're about to go shoot some GoPro footage and also go grab two more kayaks. But I just wanted to point out how nice and easy the thing is to load up one. You need a two-inch ball. If you don't got one, we do. And two, if you're like me and you have a seven pole connection, you're going to need a converter like the one I have here. So we have those two.Another thing that I like about it, you don't have to really dip down as far as the tongue is. You have this little handle. Super nice to be honest. This thing is hardly over 200 pounds, and with the kayaks, they don't really add a whole lot of weight. But with that axle being way back there is super easy to load up. So don't be afraid to load up your kayaks first. It's not necessarily a big deal. And even if you have four on here, we can unload it and keep the kayaks there. So we're ready to kayak whenever we want.So go like this and we've got to just make it to where it gets down to that ball done deal. And then one other thing that I have issues with the trailer that I use every single day is the safety chains are not long enough, but these are. They're plenty long and I absolutely love that because I usually have to rig something up to get my trailer to fit. So you will not have that issue.Well, that's just about it for a look at the Malone XtraLight LowMax trailer, and I'm Adam with etrailer.


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