ShapeArrays greater than 100 m in length are shipped in a reel crate. The bottom of reel crate is shaped like a pallet for easy lifting with a forklift. Once disassembled, the reel crate is designed to be used as a reel stand for installation and retrieval of the ShapeArray. To get the most out of the ShapeArray reel crate, it must properly be disassembled.


Figure 1: A packing crate containing a 150 m ShapeArray


The ShapeArray reel crate is assembled with Torx screws that can be removed with a T-25 Torx bit, as shown in the figure below. 


Figure 2: A T-25 Torx screw bit (left) and a Torx screw (right)


To disassemble the reel crate, only certain screws should be removed. The screws to be removed are clearly identified on each side of the crate. They are circled with arrows pointing towards them, as shown in the figure below.


Figure 3: A side view of a reel crate - the screws to be removed are circled with arrows pointing to them



Step 1 - Remove the Top Panel of the Reel Crate


To begin disassembling the reel crate, remove the screws along the top edge of the reel crate. The same screws on the opposite side of the crate will also need to be removed.


Figure 4: To remove the top panel, remove only the screws along the top edge of the reel crate


Once the screws have been removed along the top edge of the reel crate, remove the top panel of the crate and set it aside.



Step 2 - Remove the Side Panels in the Upper Section of the Reel Crate


Once the top panel of the reel crate has been removed, the top section of the reel crate can be fully disassembled. Remove the screws along the front and back edges of the top section of the reel crate to remove the top side panels. Be careful not to drop the top side panels as you remove the screws. Someone should hold these panels in place while the screws are removed to prevent injury.


Figure 5: To remove the top side panels, remove the screws along the front and back edges in the top section of the reel crate


Once the screws have been removed along the front and back edges of the top section, remove the top side panels of the crate and set them aside.



Step 3 - Remove the Front Panel of the Reel Crate


After the top section of the reel crate has been fully disassembled and removed, the front panel of the crate can be removed. Remove the remaining marked screws along the front side of the reel crate. The same screws on the opposite side of the crate will also need to be removed. Be careful not to drop the front panel as you remove the screws. Someone should hold the panel in place while the screws are removed to prevent injury.


Figure 6: To remove the front panel, remove the screws along the front edge of the bottom section of the reel crate


Once the screws along the front side of the reel crate have been removed, remove the front panel and set it aside, as shown in the figure below. 


Figure 7 - Remove the front panel after extracting the screws holding it into place