Installation Guide:

The installation of the Front Mudflaps requires good mechanical knowledge and tool skills. It is important to follow these instructions.

TOOLS REQUIRED:

• Drill
• Rivnut Crimper if you chose to use the rivnut hardware
• Socket Set/Spanner
• Sharpie
• Ruler
• Stanley Knife
• Grinder
• Clip Screwdriver
• Alan Key Set
• Masking Tape
• Paint
• Cavity Wax
• Brake and Parts cleaner
• Jack and stands

 STEPS:

1. Begin by lifting the vehicle and removing the wheel, for more room to work. Always have a jack stand holding the vehicle up, never rely on the Jack. Also keep your phone on you in case something were to fall and pin you down, so you can call for help.
2. Now remove the 10mm bolts holding the Guard Liner and Flare on. Also remove the 10mm at the front of the guard which holds the bumper bar on. Remove the Guard Liner clips with a clip screwdriver, then slide the Guard Liner towards the engine to carefully remove it. 
   
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3. If you have an RC Colorado, you can gently pull on the flare to release the clips and remove it. If you have an Ra7/D-Max, you can carefully remove the flare by reaching in behind the guard and squeezing the fingers of the flare clips in. Apply light pressure on the flare. Carefully work your way around the guard, keeping tension on the flare and popping the clips off one by one. If the fingers on the clips are hard to compress, you can use a pair of pliers to squeeze them in. Alternatively you can use an 8mm socket and slide it over the clip, which will compress the fingers and allow you to remove it.
   1. NOTE: If you break any of the clips, we sell replacements. They also have a better hold then the factory clips on an RC Colorado, so if you have issues later getting the flare to sit nice they are a good alternative. 
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4. Once the flare is removed, you can make some measurements for where to cut. This step is EXTREMELY important to get route, for a neat finish of the mudflap to guard. Along the bottom edge of the guard is texture liner, using your ruler measure 90mm from the back of the guard and put a dot, as shown below:
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5. Now, along the bottom edge/radius of the guard, measure 80mm from the back of the guard and put a dot, as shown below:
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6. Now measure 10mm down from the SECOND lowest Flare to Guard bolt, and make a straight line, as shown below:
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7. Finally, along the bottom edge of the guard where the mounting bolts are, measure 55mm from the back edge of the guard and put a mark straight up to the bend of the guard. 
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8. Now, you can use your ruler and join your points, starting at the second guard bolts and drawing a straight line to the point at 90mm and 80mm, then continuing around the guard radius to the bottom edge of the guard. You should end up with a straight angled cut along the rolled edge of the guard, as shown below.
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9. Now remove the first of the lower guard bolts, and using the grinder, chop off the marked out section, cutting along the line. If you cut a bit more off its not an issue, it will just give you a little more gap to the mudflap. 
10. You can now mark out the cabin behind the guard for cutting. You will want to draw a straight line up from the bottom guard mount section that you have just cut, to the second mount for the guard liner. Draw a line 10mm down from the hole on that second guard liner mount, and cut this off as well. Refer to the photos below.
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11. Now cut off this inner section of panel, following the line you have scribed. Be careful cutting along this circled section here, you don't want to remove too much material as it can expose the inner layers of the cab structure if you cut too deep. Once you have cut this section out (It is easier to cut it in sections), use a grinding wheel or flap disc to smooth out the cuts, particularly around the second guard liner mount. Remove the burs from the guard edge as well.
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12. Using a blower or compressed air, clean out inside the guard to remove the metal dust and filings. Use a wax and grease remover such as brake and parts cleaner to clean off the guard and cab structure. Mask up the guard and inner guard structure and paint it. We like to use a Black Zinc for good adhesion and corrosion resistance, and when the paint dries we remove the masking and spray inside the guard with cavity wax. 
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13. You can now drill out the two holes along the edge of the guard with a 9mm drill bit, and fit the supplied rivnuts. Use cavity wax and paint to protect the exposed metal after drilling.
    1. NOTE: be careful that the bracket you are drilling into does not twist, drill slowly with light pressure. 
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14. You can now refit the plastic guard liner, using the clips to secure it in place. Before refitting the flare, you will need to cut it for clearance around the mudflap. Measure around 35mm in from the OUTSIDE edge of the flare and put a mark. Now you can measure 10mm down from the second bolt hole, put a mark at the edge of the flare and join these two marks with a straight line. Cut this section of the flare off. 
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15. If the factory mudflap has been removed already, you can cut also cut off the bottom section of the flare where the mudflap secures to. If your factory mudflap is still attached, you can retain a small portion of it if you'd like to close up the gap, however you will need to cut the inside section of it off as sown below: 
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    2. You will also need to cut the mudflap around the Munji Mudflap:
16. Now that the flare is modified, it can be refitted. If any of the factory clips have broken, replace them before refitting the flare. Ensure all the flare clips have clipped in, and if you are struggling to pop them in, support the guard form behind while applying pressure on the flare. You can now bend the flap on the mudflap out 90 degrees and test fit it up to the guard, securing it to where you fitted the rivnuts earlier with the supplied countersunk M6 screws. The flap will bolt up the the lower guard bolt, and can be fitted by pushing the mudflap towards the back of the vehicle and securing it with the supplied M6 button head bolt and flat washer.
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17. Now mark the flare where the outer two holes on the mudflap are, remove the mudflap, drill the flare out with an 11mm drill bit and fit the supplied jack nuts using your rivnut crimper. Now you can remove the protective film on the mudflap and fit it up completely!
    
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18. Now you can fit your stickers on and use your extra clearance! If you have any issues with the flare not sitting flush with the guard, make sure the guard and flare have been sufficiently cut back, and none of the flare clips have popped out. We have replacement clips available if any are broken or missing. If you have an RC and the factory clips keep popping out, our replacements are a 1 piece design with more grab then the factory Holden 2 piece design, so we would recommend fitting a few to the trouble areas to hold the flare better! Any other issues please don't hesitate to get in contact with us
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If you have any issues please contact me and I am more than happy to assist.

All the best with your 4weeling. Stay safe.