am-4667 Climber In a Box
Product Information
The Climber in a Box is a versatile product that can be
assembled into either a 1-Stage (am-4667) or 2-Stage (am-4668)
climber. It includes various components such as square tubes, hook
assembly, hook plate, bearing assemblies, spacers, slider blocks,
clamp slider blocks, constant force springs, washers, nuts, screws,
winch assembly, winch plate, rope, and other hardware.
Product Number: am-4203-30
Quantity: 1
Product Photo:
Product Usage Instructions
Assemble Hook
Step 1: Align Hook Plates (am-4654) and 5 spacers (am-3876) as
shown. The hook will be used as a drill guide so additional spacers
and hardware will be added later.
Step 2: Insert a 10-32 x 1.5 SHCS (am-1014) through both plates
and spacers and secure with 10-32 Nylock Jam Nuts (am-1063).
Pre-Assemble Winch Plates
Winch plates will be installed on the outer-most box tube. The
winch plate assemblies are also used as drill guides for the box
tubes.
Step 1: Align winch plates (am-4646) and 4 spacers (am-1599 or
am-1600) as shown.
Step 2: Loosely add 10-32 screws and nuts (am-1063) to the
assembly.
Pre-Assemble 1.5 Bearing Plates
Leave hardware loose! Bearing plate assemblies will be used as
drill guides for the box tubes.
Step 1: Align 1.5 tube bearing plates (am-4644) and 4 spacers
(am-3876) as shown.
Step 2: Loosely add 10-32 screws (am-1049) and nuts (am-1063) to
the assembly.
Assembly Guide
Climber in a Box
Creates 1-Stage am-4667 and 2-Stage am-4668
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Parts Used: Component
1 x 1 x .063 30IN Square Tube 1.5 x 1.5 x 0.063 30IN Square Tube 2.0 x 2.0 x 0.063 30IN Square Tube Hook Assembly (am-4660)
Climber In A Box Hook Plate
1IN 3/8 OD .192ID Aluminum Spacer 10-32 x 1.500 SHCS 10-32 Nylock Jam Nut 1.5″ to 1″ Bearing Assembly (am-4661)
1.5″ Bearing Plate
Product Number Qty Product Photo
am-4203-30
1
am-4669-30
1
am-4670-30
1
am-4654
2
am-3876
7
am-1014
9
am-1063
9
am-4644
2
1.5″ 3/8 OD Round Spacer
am-1599
4
Spacer, 1/2 OD x .375 ID x .688 IN Long Plastic Spacer
am-1611
2
5/16 OD 1.5″ long #10 Aluminum Spacer
am-1503
2
2
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Climber In A Box Inside Slider Block
am-4629
2
Climber In A Box 1×1 Clamp Slider Block
5/16″ OD .875″ Long #10 AL Standoff
Constant force spring
5/16″ Hardened Steel Washer 608 Bearing 10-32 Nylock Jam Nut 10-32 Jam Nut 10-32 x 2000 SHCS 10-32 x 375 BHCS with Patch #10 Washer 10-32 x 500 FHCS with Patch 2.0″ to 1.5″ Bearing Assembly (am-4662) 2.0″ Bearing Plate
2.0″ 3/8 OD Round Spacer
am-4630 am-1613 am-4657 am-1009 am-4456 am-1063 am-1612 am-1049 am-1588 am-1026 am-1505
am-4645
am-1600
3
2 2 2 8 4 8 6 6 8 6 4
2
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Spacer, .47 OD x .33 ID x 1.18 IN Long Plastic Spacer
am-1610
2
5/16 OD 2.0″ long #10 Aluminum Spacer
am-1582
2
Climber In A Box Inside Slider Block
am-4629
2
Climber In A Box 1.5×1.5 Clamp Slider Block
am-4631
2
Constant Force Spring
5/16″ Hardened Steel Washer 608 Bearing 10-32 Nylock Jam Nut 10-32 Jam Nut 10-32 x 2500 SHCS 10-32 x 375 BHCS with Patch #10 Washer
10-32 x 500 FHCS with Patch
am-4657
am-1009 am-4456 am-1063 am-1612 am-1024 am-1588 am-1026 am-1505
4
2
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1.5″ OR 2.0″ Winch Assembly (am-4663)
Climber In A Box Winch Plate
1.125IN Bearing Plate
1.5″ 3/8 OD Round Spacer OR 2.0″ 3/8 OD Round Spacer 10′ Silver Dyneema Rope 10-32 x 2000 SHCS OR 10-32 x 2.500 SHCS 10-32 Nylock Jam Nut
Climber In A Box Winch Spool Half
am-4646
2
am-3722
1
am-1599/am-1600 5
am-4559
1
am-1049
6
am-1063
12
ip-4647
2
500 Hex HD Bearing
am-2986
1
10-32 x 500 BHCS
am-1512
8
.250 long . 192 ID . 375 OD AL Spacer (2.0 Winch Only) am-4209
2
1.313 long .192 ID . 375 OD AL Spacer
am-1601
1
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Assemble Hook
Hook will be installed on the 1.0″ box tube. The hook is also used as drill guides for the box tubes.
Step 1: Align Hook Plates (am-4654) and 5 spacers (am-3976) as shown. The hook will be used as a drill guide so additional spacers and hardware will be added later.
Step 2: Insert a 10-32 x 1.5″ SHCS (am-1014) through both plates and spacers and secure with 10-32 Nylock Jam Nuts (am-1063).
Pre-Assemble Winch Plates Winch plates will be installed on the outer-most box tube. The winch plate assemblies are also used as drill
guides for the box tubes.
Step 1: Align winch plates (am-4646) and 4 spacers (am-1599 or am-1600) as shown.
2.0″ Box Tube 2 Stage Assembly
1.5″ Box Tube 1 Stage Assembly
Step 2: Loosely add 10-32 screws and nuts (am-1063) to the assembly.
2.0″ Box Tube 2 Stage Assembly
1.5″ Box Tube 1 Stage Assembly
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Pre-Assemble 1.5″ Bearing Plates Leave hardware loose! Bearing plate assemblies will be used as drill guides for the box tubes.
Step 1: Align 1.5″ tube bearing plates (am-4644) and 4 Step 2: Loosely add 10-32 screws (am-1049) and
spacers (am-1599) as shown.
nuts (am-1063) to the assembly.
Pre-Assemble 2.0″ Bearing Plates (2 Stage ONLY) Leave hardware loose! Bearing plate assemblies will be used as drill guides for the box tubes.
Step 1: Align 2.0″ tube bearing plates (am-4645) and 4 spacers (am-1600) as shown.
Step 2: Loosely add 10-32 screws (am-1024) and nuts (am-1063) to the assembly.
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Tube Hole Locations for Match Drilling Tips for drilling: Keep drill bit straight and perpendicular to the tube surface. Make sure not to push too hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling. Below are images of how the tubes should look after drilling holes. Read further for full match drilling instructions. CAD files and prints are also available on our website for more details.
1″ Box Tube for 1 & 2 Stage Climbers Plate Side (Thru Holes) Spring Side (Thru Holes)
1.5″ Box Tube for 1 Stage Climber ONLY
Plate Side (Thru Holes) Winch Side (one face only) 1.5″ Box Tube for 2 Stage Climber ONLY
Plate Side (Thru Holes)
Spring Side (Thru Holes) 2″ Box Tube for 2 Stage Climbers ONLY
Plate Side (Thru Holes)
Winch Side (one face only)
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Drill 2.0″ Box Tubes (2 Stage Only)
Tips for drilling: Keep drill bit straight and perpendicular to the tube surface. Make sure not to push too hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling.
Step 1: Align the flat edge of the bearing plate with the edge of the Box Tube.
Step 2: Tighten screws to secure assembly.
Step 3: Use a #7 .201″ drill bit and drill two holes in the plate closest to the edge.
Step 4: Align the winch plate assembly to the other end of the tube. Use a #7 .201″ drill bit and drill three holes on both sides. Ensure the offset hole aligns across the tube.
Step 5: Move the winch plate assembly to the face 90 degrees opposed to the faces with the holes drilled in the previous step. Use a #7 .201″ drill bit and drill in the center hole on ONE side.
Step 6: Using a step drill bit, open up the hole in the tube to approximately 1.125″ in diameter. The rope will pass through this hole so make sure the edges are deburred and smooth.
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Drill 1.5″ Box Tubes
Tips for drilling: Keep drill bit straight and perpendicular to the tube surface. Make sure not to push too hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling.
Step 1: Align the flat edge of the bearing plate with the edge of the Box Tube.
Step 2: Tighten screws to secure assembly.
Step 3: Use a #7 .201″ drill bit and drill two holes on both sides.
For 2-Stage Climbers drill the following additional holes in the 1.5″ Box Tubes
Step 4a: Move the bearing plate assembly to the other end of tube and other face 90 degrees opposed to the faces with the holes drilled in the previous step. Use a #7 .201″ drill bit and drill three holes on both sides.
For 1-Stage Climbers drill the following additional holes in the 1.5″ Box Tubes
Step 4b: Align the winch plate
Step 5b: Move the winch plate
assembly to the other end of the tube. assembly to the face 90 degrees
Use a #7 .201″ drill bit and drill three opposed to the faces with the holes
holes on both sides. Ensure the offset drilled in the previous step. Use a
hole aligns across the tube.
#7 .201″ drill bit and drill in the
center hole on ONE side.
Step 5c: Using a step drill bit, open up the hole in the tube to approximately 1.125″ in diameter. The rope will pass through this hole so make sure the edges are deburred and smooth.
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Drill 1.0″ Box Tubes
Tips for drilling: Keep drill bit straight and perpendicular to the tube surface. Make sure not to push too hard and bend the tube surface.
Ensure all chips and burrs are removed from the inside and outside of the tube after drilling.
Step 1: Align the flat edge of the hook assembly with the edge of the 1.0″ Box Tube. Tighten screws and use a clamp to secure the hook to the tube.
Step 2: Use a #7 .201″ drill bit and drill two holes on both sides.
Step 3: Move the hook assembly to the other end of the tube other face 90 degrees opposed to the faces with the holes drilled in the previous step.Use a #7 .201″ drill bit drill bit and drill two holes on both sides.
Step 4: Move the hook assembly up one hole and secure. Use a #7 .201″ drill bit drill bit and drill a third hole in-line with the first two holes on both sides.
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Assembly
Step 1: Screw the springs (am-4657) into the 1.0″ tube using 10-32 x.375 patch screws (am-1585) and Nylock Nuts. (am1063) The head of the screw should be on the same side as the coil. The screw should be snug, but not too tight and the spring needs to be parallel to the edges of the tube.
Step 2: Attach clamp blocks (am-4630). The top holes use 10-32 flat head screws (am-1505) and Nylock Nuts. (am-1063).
Warning: Springs are sharp be careful when uncoiling and handling
Note: Climber kits sold prior to 2/1/2022 may have two standoffs for mounting clamp blocks.
Step 3: In the bottom holes use 10-32 flat head screws (am1505) and thread into a standoff (am-1613). Tie rope around the bottom standoff using a secure knot. To secure the knot it’s helpful to carefully melt the knot and end with a lighter.
Step 4: Attach spring and clamp blocks (am-4631) to the 1.5″ tube using 10-32 flat head screws (am-1505) and Nylock Nuts. (am-1063).
It may be helpful to use a wrench to hold the standoff in place while inserting the screw.
Step 5: Attach the Bearing Plate Assembly to the top of the 1.5″ Tube using one 10-32 x 0.375″ Button Head Cap Screws with thread patch (am-1588), Washers (am1026) and non-locking nuts (am-1612) in the lower hole.
Step 6: Insert the 1.0″ tube end into the 1.5″ tube so that the springs align with the top holes in the Bearing Plates.
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Step 7: Carefully insert two non- locking nuts (am1612) one into each slider block pocket as shown. Slide the slider block between the two extrusions with the nuts facing in as shown.
Step 8: Secure Inside slider blocks (am-4629) and Bearing Plate Assembly to the top of the 1.5″ Tube using 10-32 x 0.375″ Button Head Cap Screws with thread patch (am-1588), Washers (am-1026)
Step 9: Assemble the spacers, washers, and bearings through and alongside the spring as shown.
1.5″ Bearing Assembly
Step 10: Insert a 10-32 x 2″ screw through the plates and assembly and secure with a nylock nut.
2.0″ Bearing Assembly
Step 11: For the 2-stage climber, insert the end of the 1.5″ tube assembly into the 2.0″ tube and repeat steps 1-9 to attach the bearings and plates to the 1.5″ tube.
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Step 12: Attach the winch plate assembly to the outer stage tube using 10-32 button head screws and nuts.
2.0″ Winch Atachment
1.5″ Winch Atachment
Step 13: Insert 10-32 x 2.5″ screw through plate, tube and a spacers. This will help guide the rope through the hole to the spool.
1.5″ Winch Rope Guide
2.0″ Winch Rope Guide
Step 15: Press a bearing into the bearing plate and attach to the plate using 10-32 button head screws and nuts. Make sure the bearing flange is on the inside face of the plate so the bearing does not fall out during operation.
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Step 17. Secure the rope to the spool and add your gearbox to the assembly. The narrow sides of the spool face outwards. The 2-stage climber uses a 0.5″spacer to accommodate a longer rope.
Step 18. Add another spacer and secure with 10-32 screw and nut.
For more tips and video on how to choose a gearbox and tie your rope visit our website.
Step 19. Add remaining spacers and screws to complete the hook assembly.
Step 20. Attach hook to 1.0″ box tube using 10-32 screws and Nylock Nuts.
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