Portable Training Rig
Warning, Foreword & Disclaimer
The activity of aerial sports as trapeze, web, fabric, hoop etc. is a thrill seeking, daredevil type of activity.
It is extremely hazardous and should be approached with this in mind.
When doing these activities you are willfully risking life & limb.
The use of, erection of and lowering of a rig is a very dangerous activity.
The manufacture can not determine how the equipment
will be used or abused, miss-used.
Therefore:
The manufacturer takes no responsibility in:
The use of the rig,
raising of the rig
lower the rig.
Or any activity associated with the rig.
The USER (you) , knowing the extreme nature of this endeavor,
assumes all responsibility.
If the user is not willing to assume the risks associated with this sport and activity then perhaps the user should not engage in the sport and the use of this equipment, and should find a more benign activity to participate in.
PLEASE read all instructions first and make sure you understand what is needed to erect the rig.
If you have any questions, please call.
Portable Training/Performance Rig
Assembly Instructions
Please read ALL instructions through once before starting.
Tools & supplies you want to have with you.
Pliers
Mallet
Adjustable Wrenches
Allen Wrench set.
Level
Several 2x8 wood pieces about 12” long for leveling & several 1x8 wood pieces about 12” long for leveling
Several 4x4 wood about 20” long to keep header off ground during assembly.
1. There are 2 different base unit sections. One has a hinged piece and one does not have the hinged piece. You have two of each.
Bolt together each section with
the hinge to a section without the hinge.
There are two L-shaped pieces
with big eye bolts for the safety line pulley blocks. Slide the long ends with
the pulleys on them into the ends of the Crane bar section.. At this time you
can determine what width the rig is to be: 9 ½ ft. 10’ 12’ etc. When you have
set your width and the pulley blocks are equal distance from the ends of the
crane bar, tighten the 2 set screws on each end of the crane bar with the
allen wrench. ( There must be no less than 1 ft of the L shaped piece
inserted into the ends of the crane bar.)
Attach the pulley blocks to the eye bolts with the big quick links if you are
going to use the safety lines
2.
Arrange the 2 base units on the floor parallel to each other and the same
distance apart as the assembled crane bar unit is wide. With the hinged latches
open and pointing towards where the crane bar will be laying for setup. (It is
best if the bases are arranged so that the ‘T” handles on the sliders are
pointing outward.)
4
Position the crane bar about 18 feet from the Base unit hinge
plates and with the corner pieces pointing toward the base units.
Now see instructions to height extension installation if they are to be used. Suggest not using extensions first time you set rig up unless you plan to set rig up just once and then leave rig up for extended time. Rig is much harder to lift with extensions.
5
Position the 2 long upright poles, (with the cable attachment plates),
parallel to each other and in a ‘U’ shape with the crane bar. The cable
attachment plates need to be about 4 ft from the crane bar and pointing
outwards.
6
Slide the other 2 upright poles (without the cable attachment plates)
into the two sections that were just added to the crane bar.
7
Slide the two side stabilizers onto the lower sections of the ‘U’ frame.
Temporarily tighten the ‘T’ handle bolts so that the side stabilizers will not
touch the floor when rotating the ‘U’ frame to it’s vertical position. (These
side stabilizers will put a twisting moment onto the uprights while it is on the
ground during the assembly if the uprights. This twisting will make it hard to
slide the U shaped header onto the uprights. When it comes time to slide on the
header have someone lift the ends of the stabilizer to the the tension & twist
of the uprights so that the header can slide in easy.
8
While the ‘U’ frame is still on the ground, thread the nylon safety line
ropes through the pulleys blocks properly for belt use. The longer rope goes
from the pole side of the single pulley, across to, and through the double
pulley, toward the pole side of the double pulley. The shorter rope goes from
the center of the rig through the double pulley towards the upright poles. This
results in both the lose ends of the rope coming out of the double pulley in the
same direction and towards the upright pole.
It helps to have some short pieces of 4x4 wood to put under the header as it
lays on the ground. That way the cable ears are of the ground and do not dig
into the ground.
9
Attach the 14 ft wires to the cable holes in the plates which are about
4’ from the crane bar.. 2 cables on each side of the ‘U’ shape. Each cable in
it’s own hole. Arrange the cables so when the framework is lifted the cables
will not be tangled. Make sure the loops on the cables are not kinked or crooked
in the carbineer.
10
Slip the extremities of the ‘U’ frame onto the hinge sections of each
base unit. (This will be a bit awkward at first as you get the pieces lined up
and spaced properly).
Make sure all parts are now fully slid together
11
On the same side of the BASE unit where the ‘U’ frame still rests on the
ground, snap the ends of the lower cables to each eye of the two sliding
pensioner bushings of the base unit, BEFORE rotating the ‘U’ frame to the
upright position.
If you will be using the height extensions or are going to use the rig for swinging or spinning maneuver then you need to now attach the 4 guy wires to the cable tabs at the crane bar so that rig can be guyed out and fastened down to the ground.
12
If the rig is being used outdoors, it is important that the rig is close
to level. We suggest that you carry with you a carpenters level and 5 or 6 wood
leveling shims. About 12”x12” by ¾” thick., See section below on leveling
techniques.
13
Two or more strong and preferably tall men can now erect the framework.
It is helpful for a couple of other persons to keep the bases from sliding
during the process.
With the OPTIONAL easy-erection kit it is possible for two small women to
erect the rig. See the Easy-Erection kit Instruction below.
14
When the framework is upright the two hinged sections should snap into
place. Make sure the pin is fully snapped in and through the hole to hold the
uprights securely.
15
After the frame has been raised to the vertical position with the two
cables already hooked in place. Snap the other two cables into the remaining two
sliding bushings on the other side of the base.
16 At this time, make any adjustments necessary to the uprights of the ‘U’ frame to bring them 90 degrees to the floor surface. Using a carpenters level. Tighten and loosen the cables via the sliding bushings. After you determine that the rig is adjuster correctly, tighten the set screws of the sliding bushings on the hinge side of the base. Then tighten the other cables and tighten the ‘T’ handles. The slider with the set screws should not need adjustment in the future. From then on, you only need to slide the bushings with the ‘T’ handles for loosening and tightening all for cables when erecting or lowering the ‘U’ frame.
17
Now adjust the side stabilizer struts to stabilize the rig from side to
side and make it a close to vertical as you can.
To lower the rig, you need to loosen the slider with the ‘T’ handle and unsnap
the cables from the slider. Leave other side cables alone, as when ‘U’ frame
lowers the cables will always loosen.
With the Self-erection kit, lowering the ‘U’ frame is entirely different.. Be
certain to see instruction with the kit for proper and safe lowering of the rig.
18
Check the bases to see if they have moved during erection. If so
re-square them with the rig
19 If you used the height extensions or plan to do any maneuvers that include swinging or spinning then use the guy wires now to fasten rig to ground using 4 anchors and 4 ‘come-alongs’.
CAUTION: If moving the portable training rig from one spot to another, use at least four strong people , one at each corner, Be very careful to not put undue strain on the top spreader tubes of the crane bar, by varying the distance between the two base units while the base unit is being moved. ( it might help to put a rope from one base to the base on the other side, tied off at the proper distance spread. This will help in determining base spread distance as rig is being moved. )
Spread the bases apart to the width of the crane bar and get them parallel. Next lay the crane bar on one end of the 2 bases and use a level on the crane bar to determine level.
Use the wood shims to get the two base unit ends at even height. Then do the same for the other end of the two base unit ends.
At this point he rig will be level from side to side but it may still have a forward or backwards lean/
Hold the level even with the bottom of the base and determine if the front or back of the base may need some adjustment. Then do the same for the other side.
CAUTION: Make certain that the cables are all in the proper place, securely fastened and in good condition.
Be certain that cable attachment are straight, not kinked or twister.
After applying a little tension to the wires but before actual lifting.
Check ALL wire connections & makes sure they are straight. Especially the lifting cables. If they are not straight they could snap during lifting causing a catastrophe.
If the stabilizing cables are not straight then you would have to bring the rig back down to straighten them.
Use two people to raise and lower the rig. They do not have to be strong.
ABSOLUTLY do not allow anyone to stand anywhere near where the rig would fall should a cable or component break, or if you lose control of it as you raise or lower it.
We suggest that you have an old piece of carpet that you can lay under the crane bar as it lays on the floor. Not only will it help protect the floor from scratches it gives visual clue to where the rig could fall should anything go wrong and de-marks the area where people should not be any where near to during erection or lowering.
To lift rig: This takes minimum of 2 people
Install the leverage towers to the base unit with the bolts and wing nuts.
Attach the 12 ft lifting/tie-down cables to the rings by the cable tabs which are about 4’ from the crane bar.
(after the rig is up, these lifting cables can be used as tie-down cables out to the side to stabilize the rig. Use the ‘come-alongs’ to put just slight tension on the wires for stabilization. )
Makes sure cables are straight and that cable loops are not kinked on the
carbineer.
Attach the other ends of the cable to the top of the leverage towers, to the cable attachment tabs on the same side of the tower that the cable is coming from..
ATTACH the Come-alongs to the base, non-cable end of the come-along attaches to the attachment loop at the end of the base.
and attach the cable of the come-along to the top of the leverage tower
Make sure that all the quick links are screwed closed.
VERY Important. The come-along must have safety clips on the hooks so the hooks can NOT come off the tower or base by them selves.
Now attach the other come-along to the other side of the rig in the same manner.
It is now time to use the come-along to ratchet up the rig.
Set the come-alongs to the raising position. (see instructions that came with come-along)
You will need to use both come-alongs at the same time. Get help.
FIRST A WARNING:
Since the top of the rig which is laying on the ground is so far from the base, and heavy. When you first start to lift the rig using the come-along, the end of the base units of the rig where the come-along is attached will want to lift off the ground.
Put your foot on the base to hold it down. It takes very little pressure to hold it down but you MUST do it. Once the rig is about ½ way up this tendency of the base to lift will stop.
Once the rig is almost upright there will be very little tension on the come-along cables. At this time you can just go to the uprights at push them up and latch them in place. Makes sure that latches close securely.
See main rig instruction from there on for remainder of setup.
Once the setup is fully completed you can detach the lift cables and come-alongs and use them as a tie-down to stabilize the rig even more.
To lower rig: This takes minimum of 2 people
This is more difficult and more dangerous that raising the rig.
Re-attach the lift cables and come-alongs as described in the ‘lifting instructions’
Make sure the ‘Come-alongs’ and cables are securely attached to the rig, and that the come-along cables have only a couple of inches of slack.
Next slacken the sliders with the ‘T” handles but do not remove the cables yet.
Set the come-alongs to the lowering position.
Now pull out on the latch pins and let the uprights slightly tilt. There may be a tendency for the uprights to want to re-latch if you are unlatching just one side at a time. It will help to have a small block of wood, about 1”x2” ½” thick that you can stick under the hinge below the uprights so that it will not re-latch.
Once both side are unlatched slowly lower the rig using the come-alongs. You need to use both come alongs at the same time. Get help.
AGAIN WARNING: When the rig gets about 1/3 down the end of the base units will want to lift off the ground. Make sure that you have your foot on the base unit so the rig will not tip over as it comes down.
When the uprights are about 1/3 down, (when the cables on the sliders with the ‘T” have just a little slack left in them) Unsnap the cables from the sliders.
Caution not to take your foot of the base or the base will lift, if the rig is already that low.
Continue lowering the rig with the come-alongs until it is safely on the ground.