INSTALLATION INSTRUCTIONS
for an FO style button

This is the preferred method for the proper installation of a body panel using a Dzus plate, button, and spring. Here is a list of the hardware and tools you will need.

FO-style assembly

Hardware

  • Dzus plate
  • Dzus button
  • Dzus spring
  • Mounting surface
  • Body panel
  • 2 aluminum pop rivets
  • 2 steel pop rivets
  • Panel double and 4 aluminum solid rivets
    (if applicable)


 

Tools

  • Drill or punch for a 3/8" hole
  • Drill bits - #30 and 3/8", or Unibit ®
  • Dimpling tool and 2-9/16" wrenches
  • Dzus wrench
  • Transfer punch
  • Pop riveter
  • Soft hammer or rawhide mallet
  • Deburr knife
  • 100° countersink

 

1.Welded plate

Weld plate to mounting surface.

Determine where the Dzus plate is to be installed. To make a nice installation, the plate should be bent about 1/4" from the bottom at 30° to 45°. This allows the panel to lay flush against the plate without touching the weld bead. The plate is now ready to weld to the mounting surface.

 

 

 

 

 

 

 

2.Pop-rivet spring

Temporarily install spring with
aluminum pop rivets.

Install the spring on the dimpled side of the plate with 2 aluminum 1/8" x 3/16" pop rivets. Aluminum rivets are easier to drill out when removing spring for painting of chassis. Use steel rivets for the final installation.

 

 

 

 

 

 

 

 

3. Transfer punch 1 Transfer punch 2

Use transfer punch to mark hole position.

Use the transfer punch to mark the panel for the location of the buttonhole. Insert the transfer punch into the plate with the slot over the spring. Position the body panel and tap the outside of the panel directly over the punch, with a soft hammer or mallet. This will mark the position for the buttonhole in perfect alignment with the Dzus plate.

 

 

4. Drill 3/8" hole Dimple panel with dimpling tool

Punch or drill 3/8" hole, then dimple panel
with dimpling tool.

The panel is now ready to either punch or drill a 3/8" diameter hole located by the transfer punch mark. A Unibit® will work well for this job. Deburr the hole. Dimple the panel with the dimpling tool, making sure the dimple will point towards the plate. Tighten dimpler with 9/16" wrenches until flush with panel on both sides.

 

 

5.Install solid rivets

Install doubler for extra panel strength.
(optional)

If panel needs to be reinforced, use a panel doubler. Align the doubler on the panel and drill the 4 holes in the panel using a #30 drill. Countersink the rivet holes. Permanently install the doubler with solid rivets. Solid rivets make a nicer finished product. Then adjust the spring tension so the button has a positive lock when installed.

 

 

 

6.Drill out aluminum pop rivets

Drill out aluminum pop rivets and permanently
install spring with steel pop rivets

Final installation of the spring is usually done after the mounting surface is painted. This means the aluminum pop rivets must be drilled out to remove the spring. Permanently install the spring with 2 1/8" x 3/16" steel pop rivets.

 

7.Install button

A wrench, a 1/4 turn, and you're done!

Place panel with dimpled side against the plate and insert the Dzus button. The button only takes a 1/4 turn to secure the panel to the mounting surface.

 

 

 

Front and back view of a properly installed FO style button

Front and back view of a
properly installed FO style button

 

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