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Installation Instructions

The instructions below are for the Tilt-Up Rails. Click here if you are looking for the installation instructions for the Cross-Deck Models.

Our Tilt-Up Rails are designed so you can install them without having to take your houseboat out of the water. You can do it right where it is

If you can handle a battery drill and 12-volt wiring, you can install the Rails. It can be done by one person, but it is much easier with a helper.

If you are not comfortable with installing the Rails yourself, consider these options:

  1. You can ask another houseboat owner to help you. This is especially desirable if they also want to install PWC Rails on their houseboat. You can help them, and they will help you.
  2. Almost every young man who works at the marina will be experienced with a drill and 12-volt wiring. Ask around. Offer to pay them $100 after-hours to install it for you...with you helping of course. Most of these guys will jump at the chance to earn the extra cash. Refer them to this page so they can review the instructions and know what is involved.
  3. You can ask a marine mechanic to do it, but they will charge their normal hourly rate which will add up pretty fast. Installing PWC Rails doesn't require a mechanic, so we don't recommend you hire a professional to do it.

The various pictures on this website are intended as a supplement to these instructions.

We will include an abbreviated printed version with your Rails.

Click here for loading and unloading instructions.

Click here to see a unique custom installation. If your installation is not straight-forward, let us know and we will help with any customization that is necessary.

Safety

You are responsible for the safe and secure installation of your PWC Rails.

Your Rails come with stainless steel bolts and Nylock nuts. Stainless steel threads tend to “gall” from the heat generated while turning the nuts. To prevent this, we suggest using anti-seize or squeezing a little dish soap, or scraping some bar soap or Vaseline into the threads of the bolt. Even Chap Stick, or sunscreen will work. If you use a ratchet, turn it slowly so the threads don’t overheat…no faster than if you were using an end wrench.

Always wear safety glasses or goggles when drilling or doing other jobs with hand or electric tools.

IMPORTANT: If you are installing your PWC Rails over water as most of our customers do, always tether your tools and especially the Rails themselves. It is easy to accidentally kick them off the swim deck. This is even more important when you are getting ready to mount the Rails to the Frame because most of the weight of the Rails will be beyond the end of your swim deck. We recommend that you tie a rope around the curved end of your Rails and run it up over the railing on your top deck, and down to your work space. This serves two purposes: 1) It secures your Rails from accidental loss into the lake, and 2) It allows you to control the level of the Rails as you are experimenting with mounting them at the proper angle, as determined by which set of holes in which you bolt them.

We also recommend placing a floating mat under your work area so that if you drop a nut, washer, bolt, or tool, the mat will catch it.

Included

In addition to the Frame, Rails, and Winch, your PWC Rail kit includes all the hardware and parts you will need to install your Rails, including plastic spacers between the Rails and Frame. This applies to most applications. If there are special structures under your swim platform, you might need longer bolts from any hardware store.

There are 5 basic phases to the installation:

1) Mounting the frame to your swim platform wall (4 bolts, 3/8” x 1.25”) The 1 ¼” length is long enough to go through the mounting Frame and your swim platform, and/or the forward wall of your swim platform. But if you need to go through any extra thickness, you might need to get longer bolts which are available at Home Depot, Lowes, or any other hardware store.
2) Affixing the rails to the frame (two 1/2" bolts, washers, and nuts)
3) Mounting the winch (2 bolts, washers, and nuts)
4) Installing the lift arm (mounting brackets and hardware)
5) Wiring to your 12-volt source

Each of these 5 phases is described in detail below. We recommend that you read the loading and unloading instructions before reading the following installation instructions. It will help give context to the installation steps.

Primary Tools needed for installation

- Battery Drill (do NOT use 110 volt power tools around water)
- 1/2, 13/32, and 3/16 inch drill bits
- 3/8, 1/2, and 9/16 end or ratchet wrenches
- 3/8, 7/16, 1/2, 9/16, and 3/4 end or ratchet wrenches
- Tape Measure
- Black electrical tape

Tools needed for wiring

This will vary depending on where you connect your winch wiring. If you connect directly to a battery, then you will need a tool that fits the terminals on your battery, probably a 7/16 or 1/2 inch end wrench.

Please review the wiring section below to determine what you will need in terms of tools.


Unpacking your Rails

The kit is shipped with the Rails bolted to the Frame (finger tight) and the winch box secured inside the frame between the Rails. The lift-arm(s) are wrapped to one of the rail-tubes. The nuts, bolts, and other attachment hardware is in the winch box or in the holes where they will be used. While the powder coating is very durable, you will want to be careful not to drag the Rails or scratch the paint during unpacking and installation.


Choosing a Mounting Location

There are several considerations as to where to locate your PWC Rails. If your houseboat does not sit level in the water (starboard to port), you will want to mount your PWC Rail on the “high” side if the layout of everything else allows that. Remember, with the Tilt-Up Rails, you can mount them right over your ladder because they won't be in the way when tilted up. You can also mount them close beside a slide as shown here. If your houseboat is not level after your Rails are installed and your PWC is loaded you will want to offset the new weight with some cement blocks or other suitable weight in the opposite front corner of your basement. This is a common solution, even done by the houseboat factories on new boats.

For your consideration, relative to the down-force stress on your swim platform, it is strongest near the sides where the "skin" of your hull forms a "gusset support" up to the underside of your swim platform. If you think your swim platform might not be strong enough to support the down-force of your PWC, click here to read how you can strengthen it.

You need to get in the water and look behind the vertical wall of the swim platform, armed with your tape measure (keep it dry). Make sure there is no framing that will interfere with the mounting bolts and nuts. If there is, you can move the Frame a little to one side or the other. If that doesn’t solve the conflict, you can drill a new hole in the Winch Frame to the side of one of the existing holes. If possible, you DO want one or more bolts to go through a structural support as opposed to just the aluminum skin.

Rub-Rail

If your houseboat has a rub-rail along the top of the forward wall of your swim platform, you can cut a section out of your rub-rail with a hacksaw, or just mount our Frame against it with 2 bolts* going through the forward wall, and 2 bolts down through the floor. *Depending on your rub-rail thickness, you might need to get longer bolts. Click here to see a cut rub-rail.

Hard Side Railing

If your houseboat has hard side aluminum railing that is flush with the forward swim platform wall, you might need to use spacers between the Frame and the wall because of the 3/4 inch lip on the top of the Frame. In other words, the lip might press up against your railing. Of course, if you have a rub-rail and mount the Frame against it, then the lip won't be any problem.

Mounting the Frame

Hint: When drilling aluminum, if you have a 2-speed drill, set the speed to low. A slower speed will be more efficient.

The PWC Rail Frame is secured to your swim platform with 4 bolts. The most common option is 2 going through the forward wall of your swim platform as high as possible (we include several holes to choose from) and 2 going down through the floor using the most rearward holes. This actually increases the support strength of your swim platform by using the Frame as a "gusset" between the forward wall and the swim platform. This is especially helpful if you can position the Frame so the bolts are going through support framing. But you can also put all 4 bolts down through your swim deck floor or through the forward wall.

If you mount against carpet, press the PWC Rail Frame down into the carpet and against the forward wall of your swim platform as firmly as possible to compress the carpet throughout the drilling process. Use a 13/32” to drill these holes. Insert a bolt through each hole as you drill them to assure that the frame doesn’t move while you are drilling the next holes. After you have drilled all 4 holes, remove the frame and vacuum or sweep away the aluminum shavings. Then bolt the Frame in place. If you don’t have anyone to help you, you can tape the bolt heads to hold them in place while you go under your swim platform with the nuts, washers, with a 9/16” end wrench or ratchet wrench. Remember to lubricate the bolts and turn the nuts slowly to avoid seizing. This is where you will want to have a floatation mat under the work area to catch anything you might drop.

Tighten the nuts as tight as you can get them with the maximum leverage of your end-wrench. It is difficult to get good leverage while in the water, so brace yourself as best you can and get it as tight as possible. After you use your Rails a couple of times, we recommend trying to re-tighten the nuts. You should check them once a year after that.

Attaching the Rails

When you move your rails into position to attach them, we suggest you tether them with rope so they are not accidentally knocked off into the water. All it takes is a split-second slip or mistake and they can disappear. You can also place a towel on the edge of your swim platform to avoid scratching the Rail tubes as you adjust them.

Determining the Correct Angle

You will be mounting the Rail tubes into a pair of the square holes in the sides of the Frame using the 1/2" bolts. The ideal angle is when the rear of your PWC is 3 or 4 inches out of the water when loaded, and the tips of the Rails are also out of the water. Achieving this depends on more than one variable. You have to take into account how much your houseboat will lower in the water when the PWC is loaded. This will depend on the weight of your PWC and the size of your houseboat. Longer and wider houseboats won’t be affected as much as smaller houseboats. It will also depend on whether or not your gas tanks are full. Another variable is how low or high your winch is mounted on the Frame (see loading instructions), and if you direct the cable to wind up toward the top or bottom of the drum which changes the height of the bow and stern of your PWC. You will have significant control over this when winching up your PWC.

So choosing a rail-angle is a little bit of trial and error. There is nothing wrong with choosing an angle that is your best guess, loading your PWC, and if you don’t like the loaded angle, changing it…it is only a matter of changing the 2 bolts that connect the Rails to the Frame (keep them lubricated).

We suggest that you begin with an angle so that the bottom of the entry-end of the Rails is about 3 inches above the water. If you have a smaller houseboat, you might start with 4 inches above the water. Attach the Rails with the 1/2" bolts through the outside of the Frame and through the holes in the front of the Rails. Secure with a washer and nut using a 3/4” wrench. Remember to lubricate the bolts and turn the nuts slowly to avoid seizing. Tighten them until the plastic spacer can barely be rotated by hand. Tighten as described in the accompanying picture.

Some swim platforms are very close to the water, or they slope downward toward the water, or the weight of the PWC might lower the rear of smaller houseboats such that the tips of the Rails or the end of your PWC might be in the water. If you mount your rail tubes into the bottom holes and the tips of the Rails are still touching the water, you can easily solve this by adding a spacer under the Rails tubes where they pass over the rear edge of the swim platform...essentially raising the rear of the Rails higher. The spacer can be as simple as a piece of treated 2x4 or 4x4 or a composite deck board as shown in this photo. It should be screwed to the underside of the Rails so it tilts up out of the way along with the Rails and doesn't become a toe-stubber. Some customers have painted or covered their spacer with carpet.

Mounting the Winch

Mounting the winch is very simple. The winch is mounted to the frame with just 2 bolts. There are multiple sets of height-holes to choose from. The lower you mount the winch, the higher the rear of your PWC will be out of the water, but you might have to push down on the nose of your PWC as you winch it in the last couple of feet. There is nothing wrong with changing the winch position after you load your PWC if you find that you have mounted it too low or too high. We suggest you begin with the second set of holes from the top.

Notice that the winch is offset a little from the center. This is so the rope will coms off the side of the drum in the center of the Frame.

Attach the winch with the two supplied stainless steel bolts (already in the winch) through the winch and Frame, and secured with the supplied nylock nuts using a 1/2" wrench.


Test-loading Your Rails

At this point, you need to test-load your new Rails. For this test, just open your engine hatch and temporarily connect the wires to a battery or use a battery jumper box. Use the loading technique shown here.

Test-loading will let you know if you have chosen the correct angle. For instance, if the rear of your PWC is touching the water, you will want to LOWER the front of the Rails in the Frame. Depending on how long your swim platform is, raising or lowering the pivot position 1 hole up or down (1.5” between the holes) will make an even greater difference at the rear of your PWC which is 9 to 13 feet long.

When you are satisfied with the angle, proceed to the next step. But there is no rush. You can use your Rails for a weekend or two at this stage to make sure you like the angle.

CAUTION: Our Rails are designed so the keel of all PWC hulls will clear the rear cross-member. But some new designs have deeper hulls. Watch this carefully as you load and unload your PWC. If it doesn’t clear, you will want to cover the cross member with carpet or plastic to prevent damage to your keel.
Attaching the Lift-Arm(s)

The gas-filled lift arms are designed to help lift the Rails and to help hold them in an upright position when you are using your swim platform. NOTE: You must also tether them when upright as shown at the bottom of these instructions so they don't accidentally get pushed down and cause any harm. The mounting positions let the Rails rest firmly on the end of your swim platform when down, then, with a little bit of 1-handed lifting effort, they can be tilted up. The higher they are tilted, the greater the angle and power leverage of the lift-arm.

There are 7 round holes along the edges of the Frame for installing the lift arm(s). Lower the Rails. Attach the rod-end of the lift arm to one of the holes that is 1 or 2 holes LOWER than the bottom of the Rails.

Secure the ball-stud to the frame with a 5/16” nylock nut using a 1/2 ” end wrench. You will want to hold the hex-portion of the ball-stud with a thin wrench, or needle-nose pliers as you tighten the nut. Then press the socket of the rod-end of the lift arm over the ball until it snaps into place. Then snap the aluminum bracket ball stud into the cylinder end of the lift arm.

Tilt the Rails up and temporarily tie them or have someone hold them in the upright position. With the rod-end of the lift arm attached to the frame, the aluminum bracket attached to the cylinder-end of the lift arm. Tilt the Rails to the upright position. Holding them firmly against the inside of the top of the Frame, align the aluminum bracket parallel to, and within about 1/8” of the edge of the rail tubing and mark a hole as shown below. Punch a dimple into the side of the Rail to help you center the bit. You can use the supplied self-tapping screws to make the hole if you have a socket driver that you can connect to a drill, but it is much easier if you pre-drill the holes with a 3/16” bit, then you can use a ratchet wrench to finish cutting the hole and thread in the screws.

With the bracket secured tightly with the top screw, unbolt the rod-end of the lift arm, OR raise the clip on the cylinder end as shown below so that you can move the lift arm out of the way of the bottom-hole in the aluminum bracket.

With the lift arm out of the way, punch and drill the bottom hole and secure with the second screw. Slide the clip back in place and re-attach the lift arm. It is now ready for operation.

..

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We recommend that you check these screws for tightness from time to time. They generally hold very well on their own.

Note: The manufacturer of the lift arms recommends that you remove them during the winter and store them inside WITH THE CYLINDER END UP. This keeps the seals lubricated.

 

Wiring

A basic understanding of 12-volt wiring is necessary to connect the winch to a battery power source. If you aren’t comfortable with that, you can ask a friend for their help, or most marinas have employees who are very comfortable with wiring.

Most of our customers connect directly to a battery. It is permissible to connect to another 12-volt source such as a fused connection that controls another device that would not be used at the same time as your winch, but it should be able to handle at least 50 amps which would be indicated by the fuse rating and be fed by at least 8 AWG wire.

In this PWC Rail application, the winch will never “dead-load” like it might if it were used on an off-road vehicle winched to a tree. So it should never require its maximum amperage. Still, if you connect it to a power source other than the battery, the recommended wiring leading to that source should be at least 8 gauge.

The $320 upgrade Falcon Marine Grade Winch that we are including FREE if you place your order in July comes with 18 feet of sheathed 8 AWG 12-volt wiring with ring terminals on the end that you can connect to your battery. If you don't need all 18 feet, we also include a pair of ring terminals so you can cut off the excess and crimp the ring terminals on the end.

The mounting Frames have three optional-height 7/8” holes, through which you can run the wire. You will need to drill a matching hole in your swim platform wall. Most common bit sets have up to a 1/2 ” bit. The ring terminals on the end of the 12-volt wiring are just a little larger than 1/2". All you need to do is enlarge a 1/2" hole a little larger by angling the bit from one side to the other, or using a file to "ovalize" the hole a little.

There will be several support beams under your deck above or beside which you can secure the wires as high as possible away from the water. Click here to see an example of the underside of the deck and outdrive area.

If you are replacing existing rails with our Rails, you might already have wires under your swim platform to which you can connect our winch. That will reduce the length of wire needed, and avoid the need to drill a hole into your engine compartment. As an example, one of our customers replaced his older rails with a pair of ours. He connected both winches to his existing terminal that was already mounted behind a step. While both winches are now connected to the same terminal feed, he only uses 1 winch at a time, so the amp-draw is never over loaded.

If you do need to go through your engine compartment wall, you might be able to find an existing pass-through that has enough room for you to feed the winch wires through. If not, drill a hole as high up as possible. If you are installing 2 PWC Rails, we recommend you route the wires from each winch to one hole into your engine compartment. Locate the hole so that you have a good path for the wires to reach your battery or other connection location. You will want to drill through from inside the engine compartment because it will be too high to do it if you are in the water under the swim platform. Of course, you will have to get in the water to route the wires into the engine room. This drawing shows a general way to route the wires following the dotted line.

Which battery?

It doesn't matter which battery you connect to. All the batteries in your engine room are connected to a charging system, and you are only using battery power when your PWC Rail winch button is being pushed. So you can connect to the closest battery or 50-amp terminal. I have had a couple customers who don't run wiring to their engine room at all. They just use a portable battery jumper box. But that is an extra hassle when it comes to unloading and loading. Still, it is an option that some prefer.

When you have run all the wiring and are ready to connect it to your battery, connect the positive side first, then the negative side.

 

Using the Sunbrella Winch Cover

The winch cover protects your winch from direct rain. It has a grommet drain hole in the bottom in case a sideways rain makes its way into the cover. Click here to see the best way to fit the Sunbrella cover over the winch and still use the blue Winch Tether.

 

Winterization or Other Extended Periods of Non-Use

Although the winch is sealed, most customers will want to remove it for the winter and store it inside. Click here to see how easy that is.

You should also remove the lift arms and store them inside with the cylinder UP and the rod DOWN. You can remove them be prying the ball joint clip out-and-up as shown in the Installation Instructions. Be careful not to let the clip fly off and be sure to put the clip back in place for storage.. The Rails need to be UPRIGHT when you remove the lift arms, and tied securely in place for the winter.

 

Safety Tethering

There are two kinds of tethering that we STRONGLY recommend:

1) The lift arms will hold the Rails upright, but they can still be accidentally pushed down. As pictured to the right, when tilted up, ALWAYS hook the winch line around the cross member and to the back of the Winch Frame and tighten it with the “IN” button and the clutch knob engaged. This will prevent unintended lowering of the Rails which could cause serious damage or injury.

2) When your PWC is loaded and winched up, we recommend that you add the secondary Synthetic Winch Tether shown here and below. That page shows how to tie it the first time. We are including this $20 option FREE if ordered in July.

Feedback?

As you install your PWC Rails, if these instructions don’t match your installation, or if you come up with any suggestions to make these instructions clearer, please share them with me and include any pictures that can help in the explanation.

 

Questions?

If you have any questions about installation, please don’t hesitate to ask. You can reach me personally at
937-384-0003 or send an email.

 

 


 

 

 

Click here to see more pictures of our Tilt-Up Rails

Click here to see Fabrication and Welding Details

Click here to read the FAQ's

Click here to see Loading and Unloading Instructions

Click here to read about Upgrade Options

Click here to read about our Cross-Deck Loading Systems
for cruisers, yachts, and smaller boats

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