 |
1. The Kilby Trail Boss Rocker Guards are sold uncoated and so prior to this installation, Ben had his powder coated semi-gloss black. If you're looking to get yours powder coated too, expect to pay somewhere in the neighborhood of $80-$90 at a local shop. |
 |
 |
 |
| 2. Using a 10mm socket, remove the (3) bolts securing your front fender extension to the body of your Jeep. Rubicon owners will need to remove the factory rocker guards at this time. |
3. Drill out the (3) nutserts on your on your Jeep's body that were used to secure your front fender extensions. |
4. If the nutserts cannot be drilled out because they are spinning, use a pair of needle nose pliers to crush and extract them. |
 |
5. Locate the hexagonal holes on the bottom of your Jeep's tub that is normally used for factory rocker guards and drill them out using a 15/32" drill bit. Rubicon owners will need to drill out the existing factory nutserts first. |
 |
6. Insert the 5/16" nutserts provided with your Kilby Trail Boss Rocker Guards into the 15/32" holes you just drilled out on the bottom of your Jeep's tub. The nutserts have a waist on them and should just hang there until you are ready to secure them in place. |
 |
7. Take the Nutsert Installation Tool that comes with your Kilby Trail Boss Rocker Guards and insert the accompanying bolt through it so that the head of the bolt is on the smooth side. Then, thread the bolt up into one of the nutserts you just installed under your Jeep's tub until the head of the nutsert is seated in the slot of the Installation Tool. Hold the Installation Tool in place with a 7/8" wrench and then tighten the bolt down with a 1/2" socket. This will cause the nutsert to compress and secure itself to the tub. DO NOT use power tools for this step as you will need to need to "feel" when the nutsert has fully compressed to prevent stripping the threads. Repeat process on all the other nutserts. |
 |
8. Using a floor jack with a 2x4 on top of it, carefully raise and situate your Kilby Trail Boss Rocker Guard up to the side of your Jeep. Be sure to slip in the spacer bar provided between the rear half of the guard and the bottom of your Jeep's tub. Then, secure the guard to the nutserts on the bottom of your Jeep's tub using the 5/16-18 stainless steel button head bolts also provided. The longer 1.5" bolts are to be used with the holes containing the spacers. A 3/16" Allen Wrench will be needed to secure the bolts in place.
NOTE: On some Jeep's, you may find it necessary to temporarily loosen and/or remove the bolts securing the forward half of your rear fender flares in order for your Kilby Trail Boss Rocker Guards to sit properly in place. An 8mm wrench will be needed to loosen and/or remove these bolts. Once the rocker guards are installed, you should be able to reposition the flares back a bit and re-secure them in place to the factory mounting holes with little effort. |
 |
 |
 |
| 12. Using your Kilby Trail Boss Rocker Guard as a template, locate and mark the holes you will need to drill on your Jeep's tub with a center punch and hammer. |
13. Open your Jeep's doors and make sure no carpeting or wiring is in the way and then, using a 1/8" bit, drill pilot holes through the center punch marks you just made. |
14. Remove your Kilby Trail Boss Rocker Guards. Then, with the exception of the last ones closest to your Jeep's rear fender flares, drill out all the pilot holes you created earlier using a 3/8" bit. |
 |
 |
 |
| 15. Drill out the last pilot hole closest to your Jeep's rear fender flare using a 15/32" drill bit. |
16. Insert a 5/16" nutserts into the 15/32" holes you just drilled out. |
17. As you did before in step 7, secure the nutsert to your Jeep using the Nutsert Installation tool provided, a 7/8" wrench and a 1/2" socket. |
 |
 |
 |
| 18. Place the provided vinyl welting strip along the top back edge of your Kilby Trail Boss Rocker Guard and then trim both ends to the appropriate length and shape using a utility knife or scissors. |
19. Using the Kilby Trail Boss Rocker Guards as a guide, locate and mark off all the holes on the welting strips using a Sharpe marker or grease pencil. |
20. Cut out the marks you made on the welting strips using a pair of scissors. |
 |
21. As you did before in step 8, raise and support your Kilby Trail Boss Rocker Guard back on to the side of your Jeep using a floor jack and 2x4. Loosely secure it to the bottom of your Jeep using the bolts and spacer provided. Then slip in the welting strip between the top of the rocker guard and your Jeep's tub so that the bead is flush with the top edge of the guard. |
 |
 |
 |
| 22. Place the backing plate with welded nuts on it up against the inside of your Jeep's rocker panel. Make sure that the nuts are facing inward and that there's nothing between the two surfaces. |
23. Loosely secure the Kilby Trail Boss Rocker Guards to the backing plates using the 5/16-18x1" stainless steel bolts provided. |
24. The forward most bolt will be secured to your Jeep's fender using the smaller backing plate provided containing the single threaded hole and a 5/16-18x1" bolt. Simply reach up under your Jeep's fender to hold the backing plate in place while you fasten the bolt with a 3/16" Allen Wrench. |
 |
25. Verify that the welting strip is still seated properly in place and then fasten all the stainless steel button head bolts, along the side and underneath, using a 3/16" Allen Wrench. |
The Results
Here are a few different views of what your Jeep will look like once everything is installed. I should point out that the Kilby Trail Boss Rocker Guards are designed to fit perfectly with Rubicon or Sahara flares which are wider than stock. |
 |
 |
 |
 |
 |
 |
|
