Please read all of these instructions first before you start your install!

 

The TSS Series box
was built with you in mind.  It is the easiest way for you to finish your box, installing your own equipment professionally.  We have done all of the hard work for you.  Most of the wiring is done.  Install your CB Radio and install the Stereo and Speakers and you are ready to connect the antennas to the out side and you are done.

No matter which version you have just received, they all have certain aspects in common. 

 

1. The power is dropped off for the CB Radio.  Check for a plug 3pin version to plug into your CB.  We have used a heavy duty version and it will have a 5 amp fuse in it.  If your specific CB draws more current you will need to upgrade this fuse.  Check your old power plug you are now using.  If the fuse is larger than 5amps remove it and put it in the new cord.  Do Not Use Any Bigger Than What Can With The Radio To Start With!  
2. The power drop off for the stereo will be in the form of 3 wires.  One Red for ignition hookup, one for memory or battery hook up which will be yellow, and one for ground which will be black.  Hook these to the matching wires on the stereo.  If you are not sure which ones on the stereo to use, refer to your installation manual. Plug in the supplied antenna cable jack.  If It is to short you will need a short extension.  We have these or check a local stereo shop.
3. Install your speakers.  Use your supplied screws that came with the speakers and secure them to the box.  I have found that drilling a small pilot hole will assist you in the mounting.

 

NOTE TO CUSTOMERS WITH THE WEDGE BOX ON MOUNTING SPEAKERS:

We have recessed the area where the speakers are mounted to protect the cover and speaker.  Doing so limits the mounting depth for your speakers.  Most of the ones we sell will work fine unless you are using a SIDE MOUNT MIKE CB RADIO.  This version will limit the mounting depth a lot.  We have tried several ways to address this.  The best way is to use speaker extensions.  These are plastic spacers that will increase the mounting dept by 1in.  This is usually enough to fix this problem.  Sometimes moving the speaker a little off center with the spacer ring also helps.  We use one spacer ring on the side that is inhibited by the mike and usually leave the other side alone.  If you would like to do both side the same this it is okay.  We sell these spacer rings in a pack of 2.  Check this link out for these rings in our shopping cart.  Spacer Rings

 

4. Once you have your speakers mounted you are ready to hook them to your stereo.  Follow the instructions with your stereo on hook up speakers and cap off any non connected wires.
5. Make sure any tangling wires are secured with ties.  This will make it look better and ensure if you are remove things in and out of the back of the box you are less prone to unhook them.

 

You have completed the install for the TSS Series Boxes.  Once power is hooked to the truck and your antennas are placed on the mirror you are done. Enjoy your professional Trucker Box!

 

Installing your own CB Radio

Use the bracket that can with your CB and mount it to the box.  For the 3500RL it will be secured through the top or lid of this box.  Screws or rivets should be used.  At least 2 for the bracket should hold it secure.  Align up the radio protruding through the trim out hole about ¾ to 1 in.
If your radio is smaller than the opening just center it up.  IF YOU ARE USING ONE OF THE WEDGE BOXES AND YOUR MIKE IS ON THE SIDE. Position the CB as far away from the speaker hole as you can.  This might help you in the depth issue with this box

(The 3100 box would be mounted the same as above and the UPSLOCKERBOX as well.)

NOTE:  We have found that mounting the CB Radio first makes the job go a lot easier.

 
If you are mounting the CB Radio in a WEDGE BOX, use the supplied aluminum angles to secure the CB to its bottom plate.  You will have to judge the hole position for this.  For most export CB’s you will use the top two holes with the brackets turned to the outside. Temporary the brackets in place to see which holes work best.  If necessary re drill the mounting holes in the bottom plate to insure the mount you want.  For the most part it is not necessary to back strap the CB Radio, although we will sometime use a spacer or, strap together the CB and Stereo and secure this bracket to the box to insure it will not rattle loose.  This is usually a necessary precaution against vibration and especially if the stereo or CB is heavy.

 
Remember:  As you know quiet well these trucks vibrate and rattle a lot.  When you mount the equipment in the box, take a little extra precaution to insure it is solid. Use locking washers or rivets or locking nuts.

 

Installing your speakers

The only exception installing speaker in these boxes is for the WEDGE Version.  Look at the Note to Speaker Install in The Wedge Box above.  For all others please read on.

Pre drill the holes before you try to screw the speakers in place.  Use a 1/8 in drill for this.  Use when you can the screws that can with your speakers.  These will work better with the manufactures covers you have.  If the screws do not tighten up to your satisfaction use the timmer nuts most of the speaker suppliers send with your speakers.  If you use these timmer nuts be careful to hold them with pliers if they are placed on the inside and not slid on the aluminum. 

Once they have been install, use the supplied wire to connect to the stereo.  You can usually shorten this a lot.  If your radio has wires for more than two speakers, just hook to the front set or rear set.  Set the fader on the stereo to the corresponding position.  CAP OFF ALL NON HOOKED WIRES!

Installing your stereo

 

All of the boxes are cut to receive a din mount radio.  You should not have to alter the cut.  We have found that a plastic trim ring we sell will assist in mounting the sleeve based on the thickness.  This is of course an option, but one worth the price.  Its 1/8 thickness will mount the sleeve a lot tighter.                Here is the link to this in our shopping cart. Trim

The principle behind mounting the stereo is the same for all the boxes.  Secure sleeve and slide into the hole. 

NOTE:  If you would like to put a back strap on the stereo this is recommended.  Most of the stereos come with this option supplied metal strap.  If not, you can use what ever you have to fasten it the the radio and box.  Be sure to use a short nut in the back of the stereo.  To long and you have a problem.  Consult your stereo instructions for the correct length.  If you decide to strap the radio you will have to drill a hole in the box.  This is fine and can be done neat if you take the time.  We sometimes use a rivet for this. 

NOTE ABOUT INSTALLING STEREO IN WEDGE BOX:

As you notice the stereo and cb are on top of each other.  This tip will make the mount tighter and more secure.
We use a strap on the stereo and secure it to the top of the box, passing down to the CB Radio.  This strap is bent under the CB and sometimes doubleback taped to the top of the CB.  We sometimes add a long wire tie around both CB and Stereo and pull tension around both.  A stand off with the bracket is necessary to achieve this or a spacer of some kind between the two units is necessary if you use wire ties.

Securing the bottom extension on the Wedge Box

 

You have more than one option here.  The best advice we can give you is do it before you install anything in the Wedge Box.

Option 1.

Remove the bottom feet on the WEDGE BOX.. Line up the side as best you can.  Hold it secure.  The two holes closest to the rear of the Wedge, (the ones you now have after removing the bottom feet) can be use for the first set of mounting holes.  Once the boxes are held secure to each other, mark the back holes.  Remove the extension and drill these two holes.  Use a 3/16 drill to make the new hole in the extension and 3/16 size screws to mount the extension box.  Once these are tight you can drill two additional holes up front to finish the mounting.  Usually 4 screws will do for this.  Use screws and lock washers.  When we do this for a customer we sometimes add larger washers to make sure it is mounted secure.  We use fender washers that you can buy at Home Depot or auto supply stores.  These larger washers aid in distributing the screws securing ability.  Tighten these screws well.  Having to go back and retighten after all of your equipment has been install is a pain.   

Option 2.

Some might want to use the same hasps we use on the boxes.  These hasps would allow you to remove the extension if you need to.  This is a good way if you are adding the extension after all the equipment has been installed.  You can purchase them through us .  We do not have these in our shopping cart.  If you need a set call us and we will be glad to sell you a set.

 

You will need to be precise when you use these hasps if not they will not pull tight. 

 

Connecting power to box and truck

 

If you did not purchase a connect cable from us you will have to make your own.

You can do this of course with a little effort.  We use single stranded wire of this.  Double stranded is hard to come back in any size above 12ga.  Taking in consideration the amperage draw of the equipment in your box. This will be the way to judge wire size.  We have found 8ga. always works.  We use a 6 foot length.  This will for the most part reach to the hook up on the truck.  It can be longer if you desire.  You will need some type of fitting on the end to secure it to the trucks binding posts.  We use copper alligator clips.  These are a very good grade and should last for years.  We solder them onto the wire. 

 

Now lets address the connection on the box.  We have used several different devices over the years to achieve this connection.  Others are using a similar connection found on CB’s, or some kind of polarized device.  These types are too small and were not designed to plug and unplug like you do.  We have found that the one we use will do the job for years.  Have you ever had to replace a plug at home, a receptacle plug in the wall?  This was the reason we used this type of connection.  It will last for years without replacing and allows a larger wire size if we need to use it.  We use a heavy duty polarized version 3 prong style and it works out great.  You can’t plug it in wrong if you tried. If you did not buy one from use you can pick one up at Home Depot.  Here is a link to the one we sell.  Plug and Rec

 

Note about connecting to truck binding posts. 

This connecting is usually fused on the truck at 20amps.  You cannot exceed this 20amp draw without blowning or triggering a breaker.  If your equipment draws more than this you will need to find another connection point.  Most trucks have a connecting point below the fuse box that comes up from the battery compartment.  This would be a good place for the extra power if needed. 

 

HOOK IT UP BACKWARDS DID YEA?

 

You can prevent this problem by using the common sense rule.  Hook to the truck once and check for polarity twice and then hook to box.  Be careful when doing this because the binding posts are usually hot all the time.   When you make the truck connection first the box plug end is also hot and if it touches metal you are screwed.  We have a better way

Box Saver  Select for link to shopping cart.

The Box Saver is a device we build in house to prevent this little mistake.  We install it in all of our TSS Series Boxes.  This little aluminum box will save your equipment if you hook up backwards.  No time wasted or money spent at the CB Doctor. 

Inside this device is a circuit that will stop current reaching your equipment by the use of (2) 20 or 30 amp fuses.  If hooked up backwards these fuses will blow and all you have to do is replace them with same value fuse.  After doing this you are back in business. When we install this in the TSS Box we also include a spare set of fuses for a one time BOO BOO.  A lot of our customers swear buy this little device.  It is money well spent.  Cost less than one trip to the CB Doctor.  Keeps your equipment working for this trip.

Installing Satellite Radio

 

Note:  The Aluminum Box Company recommends using a Satellite ready radio. 

 
External mount units. 

Wedge box mounting.  We found the area above the stereo to be the most desirable for placement of this type.  You will have to be creative with the hardware that came with your unit.  Modifying the brackets a little will achieve good results.  The antenna hook up is a little nasty to hook and unhook.   You can use our Satellite Cable Box wire for this.  It will locate a connector on the box just like your CB Radio and FM.  It makes for a much easier way of connecting.  Here is a link to this cable. Satellite Box Connector

Care must be taken when the unit is exterior mounted.  The cover for the box might have to be modified as well.  External mounting makes it a lot easier to hit the Satellite Unit.

 

If you are using another box version finding a suitable mounting sport is up to you.  The 3500rl has space around the external speaker, and the 3100 and UPSLOCKERBOX are limited for this application.  This is why we recommend a Sat Ready Radio.  All components are installed in the interior of the box.  The control for the Satellite is on the face of the Stereo.

 

Check back often to this section of the blog   Bookmark it so you can refer to it.  We will be posting updates to the help section when needed.  Thanks.  The Aluminum Box Company Tech Dept.