INSTRUCTIONS FOR ASSEMBLING FLYER RACKS FIGURE 1. Exploded view of flyer rack. Erwin S. "Filthy Pierre" Strauss |-----------| |-----------| |-----------| 10 Hill St. #22-L |\|-----------| |\|-----------| |\|-----------| Newark, NJ 07102 |_| | |_| | |_| | (973) 242-5999 |___________| |___________| |___________| |-----------| |-----------| |-----------| file C:\V\RACKAWUN.WK! (with underscores) |\|-----------| |\|-----------| |\|-----------| FIGURE 2. Back riser assembly. |_| | |_| | |_| | ## __________ ______________ _________ May 15, 2003 |___________| |___________| |___________| ## |_ |___| |___| _| |-----------| |-----------| |-----------| ############ | : | R | | E| : | revised April 14, 2015 |\|-----------| |\|-----------| |\|-----------| ## ## | : ~~~ ~~~ : | |_| | |_| | |_| | ## ## ___| : : |___ |___________| |___________| |___________| ## | ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ | ## |-----------| |-----------| |-----------| ## | | # STEP #1. Insure all parts are on hand, |\|-----------| |\|-----------| |\|-----------| ## | | # according to the following list (the portion |_| | |_| | |_| | ## ## | | # of Figure 1. to the right of each item in the |___________| |___________| |___________| ## ## | : : : : | ##### list, illustrates the item). |-----------| |-----------| |-----------| ## #######| : : : : | |\|-----------| |\|-----------| |\|-----------| ## ## ## | : O O : O O : O O : | |_| | |_| | |_| | ## ## ## ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ POCKET INSERTS (21 required) (set of 21 |___________| |___________| |___________| ## ## ## usually kept in one-gallon Ziploc plastic |-----------| |-----------| |-----------| ## ## ## bag) (see Figure 11. for larger-scale, |\|-----------| |\|-----------| |\|-----------| ## ## ## more-detailed, illustration of an insert). |_| | |_| | |_| | ## ## ## Before unpacking them, to be sure you |___________| |___________| |___________| ## ## ## ## ## understand how to re-pack them, look at the |-----------| |-----------| |-----------| ## ## ## ## ## last two paragraphs of the instructions for |\|-----------| |\|-----------| |\|-----------| ## ## ###### Step #12, and at Figure 12. Then, as you |_| | |_| | |_| | ## ## #### unpack the inserts, note how they are packed. |___________| |___________| |___________| ## ## FIGURE 7. Assembled flyer rack ## __________ ______________ _________ ## ## __________ ______________ _________ | | | Wide prong | | |############################# ## |_ |___| |___| _| BACK RISER EXTENSION | |___| |___| | ## | : F | R | E E B I| E| S : | (1 required) | : Narrow notch : | ## // | : ~~~ ~~~ : | (smallest piece of fiberglass; has three | : : | ## \// ___| : : |___ / wide prongs, two narrow notches) ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ## \|\ ~~~~~~~~~~~~\~~~~~~~~~~~~~~~\~~~~~~~~~~~~~~ |/ \\ ___________________________________________ ## | \ \ \ \| \\ | : F R E E B I E S : | ## | : \ : \ : \ : |\__ | : : |################################ | : |~:\| : |~:\| : |~:\| : |~:\| ___| |___ | : | : |\__ : | : |\__ : | : |\__ : | : |\__ MAIN BACK RISER | ___ ___ ___ |___ | : | : |~:\|_____:_| : |~:\|_____:_| : |~:\|_____:_| : |~:\| (1 required) | | | | | | | | | | : | : | : |\__ : | : |\__ : | : |\__ : | : |\__ (has "FREEBIES" sign) | : | |___ : | |___ : | |___ : | |___ | : | : | : |~:\|_____:_| : |~:\|_____:_| : |~:\|_____:_| : |~:\| | : | | |_____:_| | |_____:_| | |_____:_| | | |~~~| : | : | : |\__ : | : |\__ : | : |\__ : | : |\__ | : | : | |___ : | |___ : | |___ : | |___ | | : | : | : |~:\|_____:_| : |~:\|_____:_| : |~:\|_____:_| : |~:\| | : | : | | |_____:_| | |_____:_| | |_____:_| | | | ~~~| : | : | : |\__ : | : |\__ : | : |\__ : | : |\__ ~~~| : | : | |___ : | |___ : | |___ : | |___ | | : | : | : |~:\|_____:_| : |~:\|_____:_| : |~:\|_____:_| : |~:\| | : | : | | |_____:_| | |_____:_| | |_____:_| | | |O ~~~| : | : | : |\__ : | : |\__ : | : |\__ : | : |\__ ~~~| : | : | |___ : | |___ : | |___ : | |___ | ===--O | : | : | : |~:\|_____:_| : |~:\|_____:_| : |~:\|_____:_| : |~:\| MIDDLE RISERS | : | : | | |_____:_| | |_____:_| | |_____:_| | | | ~~~| : | : | : |\ : | : |\ : | : |\ : | : |\ (6 required) ~~~| : | : | |___ : | |___ : | |___ : | |___ | | : | : | : |_:\ _____:_| : |_:\ _____:_| : |_:\ _____:_| : |_:\ [have four narrow prongs (taller than those on | : | : | | |_____:_| | |_____:_| | |_____:_| | | | ~~~| : | : | :~| : | :~| : | :~| : | :~| front riser, below), three wide notches-- ~~~| : | : | | : | | : | | : | | |O | : | : | : |_________:_| : |_________:_| : |_________:_| : | but no "FILTHY PIERRE" sign] | : | : | |___ _____:_| |___ _____:_| |___ _____:_| |___ /|___ ~~~| : | : | : | : | : | ~~ ~~~| : | : | | : | | : | | : | | // ~~~---___ | : | : | : | : | : | | : | : | |_________:_| |_________:_| |_________:_| | ~~~~---___ ~~~| : | : | : |FILTHY PIERRE: | FRONT RISER ~~~| : | : : : | ~~~--| :_| Q Q :_| Q Q :_| Q Q :_| (1 required) | : | : : : : | ~~~~~~~\~~~~~~~\~~~~~~~\~~~~~~~\~~~~~~~\~~~~~~~\~~~~ [has four narrow prongs (shorter than those on ~~~| : : : FILTHY PIERRE: | \\ \\ \\ \\ \\ \\ middle risers, above), three wide notches -- and | : O O : O O : O O : | has "FILTHY PIERRE" sign] ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~~ \ \ \ I \ \Undoub-\ \ \ \ n \ \ led \ INSERT-SUPPORT DOWELS \ \ \ s \ \ ends \ (6 required) (28" long; \ \ \ e \ \ of \ note that they are 3" \ \ \ r \ \ dowels\ SHORTER than the two \ \ \ t \ \ \ cross-brace dowels \ \ \ - \ \ \ shown below, and have no safety |\ \ \ \ s \ \ \ pins, nor holes for them) |\ |O:\ \ \ \ u \ \ \ |\ |O:\ | : \ \ \ \ p \ \ \ STRINGERS |\ |O:\ | : \ | : :\ \ \ \ p \ \ \ (4 required) |O:\ | : \ | : :\ | : : \ \ \ \ o \ \ \ (big, roughly-triangular pieces) | : \ | : :\ | : : \ | : :\ \ \ \ r \ \ \ | : :\ | : : \ | : :\ | : : \ \ \ \ t \ \ \ [The slots on the stringers -- shown | : : \ | : :\ | : : \ |O : :\ \ \ \ \ \ \ here as vertical rows of dots -- are | : :\ | : : \ |O : :\| : : \ \ \ \ d \ \ \ actually cut at an angle, so that the | : : \ |O : :\| : : \ : :\ \ \ \ o \ \ \ risers will lean backward. The slots |O : :\| : : \ : :\ : : \ \\ \\ \\ w \\ \\ \\ and risers are shown as vertical, | : : \ : :\ : : \ : :\ e Doubled because that's so much easier to il- | : :\ : : \ : :\ : : \ l ends lustrate using the spreadsheet soft- | : : \ : :\ : : \ : :\ s of ware that prints these instructions.] | : :\ : : \ : :\ : : \ dowels | : : \ : :\ : : \ : :\ CROSS-PIN DOWEL(see *NOTE below right)|O : :\ : : \ : :\ : : | ===--------------------------------------------- O : : \ : :\ : : | : | Doubled end of dowel | \\ : :\ : : | : | : | | \\ : : | : | : | | CROSS-BRACE DOWELS | End with : | : | | | (2 required) |O safety pin : | | |---___ | (31" long; note that l /|___ (or hole for one) | |---___ | ~~~---___| they are 3" LONGER e /\\ ~~~---___ |---___ | ~~~---___| \ C than the six w / \\ ~~~~---___ | ~~~---___| // \ r insert-support o / End with safety pin ~~~---___| // \ o dowels shown above, d / through hole in dowel \ s and have a safety pin / (or, at least, hole \ s through one end (or, e / for safety pin: safety \ - at least, a hole c / pins may be in a \ b for a safety a / separate bag). Remove \ r pin: safety r / pin to insert dowel, \ a pins may be b / then replace pin after \ c in a sep- - / insertion. \ e arate s / \ pill s / \ d jar).o / \ o r / *NOTE: The racks made of .045" red plastic use a cross-pin dowel, instead of the two \\ w C / cross-brace dowels (the racks made of .020" pale green fiberglass material use the e / cross-brace dowels, but no cross-pin dowel). The cross-pin dowel is the same length as l / the insert-support dowels, but has a safety pin (or, at least, a hole for one) in one end. // Doubled end of dowel #### STEP #2. Assemble the back riser assembly (see Figure 1. and Figure 2. above, for "before" and "after" views). Mesh the two slots on the bottom of the back riser extension, with the two slots # on the top of the main back riser. Some back risers, and back riser extensions, have six slots (instead of two) along their tops and bottoms, respectively. Note that the four middle slots are # taped over; ignore them. # ##### Set the completed assembly aside, for later use. Note that: A). The "FREEBIES" sign faces front; B.) The "Reward" label on each piece faces backward; and C.) The middle (main) part of the back riser extension (i.e., between the slots) goes in FRONT of the "FREEBIES" sign; the side parts of the back riser extension (outside the slots) go BEHIND the main back riser. #### STEP #3. On a table, lay out the remaining fiberglass pieces: FIGURE 3. Setup for meshing stringers with front riser. # ## Put the four triangular stringers in a stack, convenient to your LEFT hand (if ______________________________________________ # left-handed, reverse "left" and "right"), with the slotted edge to the right #\ ___________ \ #### (see Figure 3.). ##\ \ שש| ______ ______ \ FIGURE 4. Meshing first stringer with front riser. ## \ \ שש| \שש __\ \שש __\ \ _____ Put the six middle risers (with the Reward" labels face down, and slots facing ## \ \ שש| \ \__ \ \__ \ ___________________________|שש __|_________ left) in a stack convenient to your RIGHT hand. Leave a work space between the ## \ \ שש| \שש __\ \שש __\ \ #\ ___________ ________| | \ stacks, wide enough for a stringer to lie without overlapping either stack. ## \ \ שש| \ \__ \ \__ \ ##\ \ שש| \ | |__ ______ \ \ \ שש| \שש __\ \שש __\ \ ## \ \ שש| \ |שש __| \שש __\ \ Put the front riser between them, slots facing left (Figure 3.). \ \ שש| \FP\__ \ \__ \ ## \ \ שש| \ | | \ \__ \ \ \ שש| \שש \ \שש \ \ ## \ \ שש| \ | |__ \שש __\ \ # # STEP #4. Mesh the triangular stringers with the front riser: \ \ / ~~~~~~ ~~~~~~ \ \ \ שש| \ |שש __| \ \__ \ # # \ \/ \ \ \ שש| \ |F | \שש __\ \ ##### Hold the front riser in your RIGHT hand, standing it on the narrow end closest to the \_____________________________________________\ \ \ שש| \ | P|__ \ \__ \ # "Filthy Pierre" sign, with the sign facing you, and the slots facing to your left. ## ## \ \ שש| \שששששש| \שש \ \ # ## ## \ \ / \ /~~ ~~~~~~ \ Pick up (with your LEFT hand) the top stringer in the stack, and mesh its FRONT slot ## FP = "FILTHY PIERRE" sign ## \ \/ \/ \ (the slot closest to you) with the BOTTOM slot on the front riser (Figure 4.). ## ## \__________________________________________\ ## ## ## ## Similarly mesh the front slot of the next triangular stringer on ## F ## the stack, with the NEXT-HIGHER slot on the front riser. ## P = "FILTHY PIERRE" sign ## ## ## Repeat for the third and fourth stringers. ## ## ##### STEP #5. Turn the stringer-and-front-riser assembly upright, as follows: FIGURE 5. Rotating the stringer/front-riser assembly. # ___________________________________________ #### Grasp the top edge of the front riser with your LEFT hand, freeing up your RIGHT #\ \ # hand to grasp the far ends of ALL FOUR stringers at once. ##\ |\ |\ |\ |\ ______ \ #### ## \ || || || || \שש __\ \ Now, rotate the whole assembly ninety degrees to the LEFT (counterclockwise), so ## \ |:\ |:\ |:\ |:\ \ \__ \ that the long end of the front riser sits on the table, with the "Filthy Pierre" ## \ | | | | | | | | \שש __\ \ sign reading right-side-up. \ | :\ | :\ | :\ | :\ \ \__ \ FIGURE 6. Meshing rearmost middle riser with stringers. \ \ | \ | \ | \ | \שש __\ \ __________________________________________ Figure 5. shows the triangular stringers standing neatly on edge. Ha! Don't we wish. \ \:\__ \:\__ \:\__ \:\__ \ \__ \ #\ \ Actually, they'll be trying to wobble and fall down; so hold on tight with your right hand. \ \|\ |_\|\ |_\|\ |_\|\ | \שש \ \ ##\ __ __ __ __ ______ \ \ | || | |Fil.P|| ~~~~~~ \ ## \ ||||__||||__||||__|||| \שש __\ \ #### STEP #6. Insert the rear-most middle riser: \ ~~~~~~~~~~~~~~~~~~~~ \ ## \ ||:\___|:\___|:\___|:\| \ \__ \ # \__________________________________________\ ## \ | | | | | | | | \שש __\ \ #### Grasp the top backs of ALL FOUR triangular stringers with your LEFT hand, freeing up your RIGHT ## ## \ | :\ | :\ | :\ | :\ \ \__ \ # # hand to pick up one of the middle risers. ## ## \ \ | \ | \ | \ | \שש __\ \ # # ## Fil.P = "FILTHY PIERRE" sign ## \ \:\__ \:\__ \:\__ \:\_ \ \__ \ ### With the "Reward" label on that middle riser facing backward, mesh it with the four stringers. ## ## \ \|\ |_\|\ |_\|\ |_\|\| \שש \ \ DON'T use the slots at the very top back of the stringers. Instead, use the next slots forward. ## ## \ | || | |Fil.P| ~~~~~~ \ \ ~~~~~~~~~~~~~~~~~~~ \ This is the trickiest part of the whole process, because the stringers will be wobbling around. \_________________________________________\ Here's a tip: concentrate first on meshing the two middle slots on the riser, with the two ## ## middle stringers (lean the outer stringers inward, to keep them from falling flat). Then mesh ## ## the outer riser slots with the outer stringers, one at a time. ## Fil.P = "FILTHY PIERRE" sign ## ## ## The assembly will now be able to stand up on it's own. Square it up, as shown in Figure 6. ## ## ##### STEP #7. Mesh the other five middle risers with the stringers, putting them between the front riser, and the rear-most middle riser just meshed (see Figure 1. and Figure 7., above, for "before" and # "after" views). # # Remember to keep the "Reward" labels facing backward. # ### STEP #8. Go around to the back of the table, and mesh the back riser assembly with the stringers (see Figure 2. and Figure 7., above, for "before" and "after" views). It goes in the back slot on # # each stringer -- the only slots on the stringers still unused. ### # # Be sure to put the bottom edge of the back riser extension DOWN INTO the slots on the two inner stringers. This will insure that the extension lies flat on the "FREEBIES" sign, allowing the sign to ### be visible through the overlying fiberglass. ### STEP #9. Still working from the back of the table, it's time to insert the diagonal cross-bracing dowels (these are the two LONGER dowels, with safety pins -- or holes for pins -- at one end; if # # using racks with cross-pin dowels instead, skip down to the next paragraph). First, SLIDE the rack so its back edge overhangs the back edge of the table (SLIDE the assembly, don't lift it: if you #### lift by the stringers, whichever stringers you're not lifting will fall out; if you lift by the risers, the risers you lift will come out, leaving behind the rest of the rack). Start one dowel # (after removing the safety pin) through the hole at the back BOTTOM corner of the left-most or right-most triangular stringer. Pass it through the NEXT-HIGHER hole at the back of the next ### stringer, and so on, until it goes through the hole at the TOP back of the stringer on the far side of the rack (some stringers have an extra hole or holes; these extras are taped over; ignore them). The dowels may tend to bind up in the holes. To deal with this, the best approach is to twirl the dowel back and forth, while pushing it in, with one hand; and with the other hand, manipulate the fiberglass where it's binding. Replace the safety pin, and repeat the process with the other dowel, starting from the other side of the rack. If using racks with a cross-pin dowel instead of two cross-brace dowels, remove the safety pin from the dowel, and run it horizontally through the holes found approximately in the center of the triangular stringers. Then replace the safety pin. The assembly can now be picked up, if necessary. Do this by grasping the two middle triangular stringers, at the points marked "GRIP HERE." But be careful--it's easy for the side stringers to work free, and the assembly to start falling apart. When a rack is loaded with flyers, it's particularly easy for this to happen; so try to avoid moving a loaded rack. ## ### STEP #10. Returning to the front side of the table, prepare to put in the insert-support dowels (see Figure 1. and Figure 7., above, for "before" and "after" views). First, position the rack # # # (SLIDING it is still better than lifting) so that its front edge (with the "Filthy Pierre" sign) is flush with the front edge of the table, or even overhanging it a bit. This will allow # # # putting in the six insert-support dowels. Insert each one through one of the holes along the bottom edge of the front riser, and work it back through each of the other risers, including the # # # back riser. Insure that each dowel goes through the corresponding hole in each riser (and doesn't pass under the riser, instead). To deal with the dowels binding up on the fiberglass, the ##### ### best approach is to twirl the dowel back and forth, while pushing it in, with one hand; and with the other hand, manipulate the fiberglass where it's binding. [You might think the doubled end of the insert- support and cross-brace dowels should be at the top end, to keep gravity from pulling the dowels down. But the way the fiberglass sheets work on the dowels tends to pull the dowels UP; so the doubled end is needed at the BOTTOM, to keep the dowels from being pulled free of the fiberglass on that end.] ## ## STEP #11. Insert the 21 pocket inserts (note that the rack has seven rows of three pockets each), like this: Hold each insert, in turn, FIGURE 11. Pocket insert # # by its stapled edge, with the flat side of the staples (not the prongs) facing you. Push the insert down into the pocket firmly (it may # # pop back up some; you can try to push it back down, but this is mainly a matter of aesthetics: once flyers are put in, they'll keep the Stapled edge # # inserts down; one tip to reduce popping up: take the edge by the staples, and fold it forward). YOU'RE ALL DONE!!! Just put the rack ||~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~| ##### ##### where it's needed, and let people load in flyers. Now that the pocket inserts are in, the rack is a little more solid. But you still || Staple Staple Staple | need to be careful when moving it -- especially so if you HAVE to move it when it's full of flyers. || ==== ==== ==== | | \~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~\ To disassemble the rack, see Step #12. | \ /|~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~| | \ / | | | ~~| | ## #### STEP #12. To prepare the rack for disassembly, first empty it of all flyers. | | | # # | | | # # Then, turn the rack upside down, laying it on a table on its slanted front, so that the back riser (with the "FREEBIES" sign) hangs over | |___________________________________________| # # the back of the table. |___________________________________________| ##### ##### Remove the cross-brace dowels. To deal with the dowels binding up on the fiberglass, the best approach is to twirl the dowel back and forth, while pulling it out, with one hand; and with the other hand, manipulate the fiberglass where it's binding. The four triangular stringers can now be lifted up and toward the front of the rack, clear of the risers. Now, grasp the middles of two of the insert-support dowels, and lift up. The pocket inserts will drop free. Push them out of the way, for now. Lifting the assembly by the dowels will also cause the risers to hang vertically. This reduces the dowels' tendency to bind on the fiberglass. Work the risers back off the dowels, starting with the back riser. When you get down to, say, the last three or four risers, it may be easier to push those risers together, and then pull out each dowel, in turn. The twenty-one pocket inserts are stacked up in pairs. Figure 12. illustrates how the inserts within a pair are partially overlapped, so that a stack of two has exactly two thicknesses of posterboard at every point (the twenty-first insert is put atop the stack of twenty, as if there were going to be a twenty-second insert). The finished stack of twenty-one inserts is then inserted into a one-gallon Ziploc bag, with the stapled edge of the top (unpaired) insert going in first. FIGURE 12. Side view of pair of pocket inserts, stacked for packing. _________________ ____________________________________ ___/ --- ------------------------------------- ----------------/ Stapled edge of first (bottom) insert, flat sides of staples face up Stapled edge of second (top) insert, flat sides of staples face down