Pelican Handle and Latch Replacement Instructions

Step 1: Remove Existing Handle(s)
a) Please be aware that each handle pin has one clean end and one end with ridges that anchor the pin in
the plastic.
b) Visually identify the ridged end of each pin. You will see ridge marks in the plastic around the
circumference of the pin.
c) When removing each pin, orient the case so that the opposite (clean) end of the pin is facing upward. You
will strike the clean end when removing each pin.
d) Carefully set a tapered pin punch* in the center of the clean end of the pin, apply downward pressure, and
strike the pin punch forcefully with a hammer to loosen the pin.
e) Using a 1/8" (3mm) or smaller pin punch**, gently tap the pin out of its hole. Reorient the case as
necessary and repeat the process to remove any additional handle pins and remove the handle(s).
Step 2: Install Replacement Handle(s)
a) Line up replacement handle(s) and insert the handle pins in the same orientation by which they came out,
inserting the clean end first. You will now strike the ridged end.
b) Using the butt end of a 1/8" (3mm) or greater pin punch** gently tap pin into place until the ridged end is
flush with the handle plastic. Greater force may be necessary once the ridges engage the plastic.
c) Reorient the case as necessary and repeat this process to reinstall all handle pins.
Step 3: Remove Existing Latches
a) Please be aware that each latch pin has one clean end and one end with threads that anchor the pin the
plastic. The clean end will be recessed in the pin hole, while the threaded end will be flush with the
plastic.
b) Visually identify the clean, recessed end of each pin.
c) When removing each pin, orient the case so that the clean, recessed end of the pin is facing upward. You
will strike the clean end when removing each pin.
d) Carefully set a tapered pin punch* in the recessed pin hole and strike the pin punch forcefully with a
hammer to loosen the pin.
e) Using a 1/16” (1.5mm) pin punch*** gently tap the pin out of its hole. You may need to grip the threaded
end with pliers to pull the pin all the way out. Reorient the case if necessary and repeat the process to
remove any additional latch pins, then remove the latches.
Step 4: Install Replacement Latches
a) Line up replacement latches and insert the latch pins in the same orientation by which they came out,
inserting the clean end first. You will now strike the threaded end.
b) Using the butt end of a 1/8” (3mm) or greater pin punch** gently tap the pin into place until the threaded
end is flush with the plastic. Greater force may be necessary once the threads engage the plastic.
c) Reorient the case as necessary and repeat this process to reinstall all handle pins.
For optimal results Pelican Color Case recommends *Stanley Fatmax 7” (178mm) or equivalent tapered pin
punch, **Stanley 1/8” (3mm) or equivalent pin punch, and **Stanley 1/16” (1.5mm) or equivalent pin punch.