SHOP 3 Door Preparation - Therma

SHOP 3 Door Preparation - Therma
SHOP 3 Door Preparation
Stile, Rail and Reinforcement Block Sizes and Locations ......................................................................... 3.3
90 Minute Positive Pressure Steel Fire Door Reinforcement Sizes & Locations ..................................... 3.5
Door Slab Trimming ....................................................................................................................................... 3.6
Door Slab Resizing ......................................................................................................................................... 3.7
90 Minute Fire Door Slab Resizing...............................................................................................................3.11
Slab Repair .................................................................................................................................................... 3.12
Hinge Preparation (Except 90 Minute Steel Fire Door) ............................................................................. 3.15
Hinge Preparation Arch Top Door ............................................................................................................... 3.16
Hinge Preparation Radius Top Door ........................................................................................................... 3.17
Hinge Preparation (Except 90 Minute Steel Fire Door) ............................................................................. 3.18
Lock Preparation (Except 90 Minute Steel Fire Door) ............................................................................... 3.19
Lock Preparation 90 Minute Steel Fire Door .............................................................................................. 3.21
Multipoint Lock Preparation (Except Fire & Steel Doors)......................................................................... 3.23
Classic-Craft Panel Installation ................................................................................................................... 3.31
Doorlite and Panel Preparation ................................................................................................................... 3.33
Doorlite & Designline Panel Installation..................................................................................................... 3.35
Impact Doorlite Installation ......................................................................................................................... 3.40
Hinge Installation.......................................................................................................................................... 3.41
Door Bottom Selection & Installation ......................................................................................................... 3.44
Grille Installation .......................................................................................................................................... 3.47
Lite Divider Installation (Classic-Craft) ...................................................................................................... 3.50
SDL Bar Installation (Smooth Star / Fiber Classic) ................................................................................... 3.52
Dentil Shelf Attachment (Classic-Craft)...................................................................................................... 3.57
Dentil Shelf Attachment (Smooth Star / Fiber Classic) ............................................................................. 3.59
5DLQ'HÁHFWRU,QVWDOODWLRQ ........................................................................................................................... 3.60
Decorative Hinge Strap & Clavos Application ........................................................................................... 3.61
Special Shop Painting .................................................................................................................................. 3.64
Special Shop Machining .............................................................................................................................. 3.65
Shop 3
2014 (U1 REVISED)
3.1
Door
Preparation
Door
Preparation
3.2
2014 (U1 REVISED)
Shop 3
Stile, Rail and Reinforcement Block
Sizes and Locations
6/8 AND 7/0 SMOOTH STAR AND FIBER CLASSIC BLOCKING OPTIONS
NOTE: FULLY BLOCKED NOT AVAILABLE IN FLUSH GLAZED.
"(C)"
"(L)"
"(C)"
"(C)"
"(C)"
"(K)"
"(K)"
"(E)"
Door
Preparation
"(C)"
"(K)"
"(E)"
"(E)"
"(E)"
"(E)"
"(J)"
"(H)"
"(H)"
"(H)"
"(J)"
"(H)"
"(H)"
"(B)"
"(B)"
"(G)"
"(G)"
"(A)"
HINGE
SIDE
HINGE
SIDE
HINGE
SIDE
"(B)"
"(A)"
LOCK
SIDE
HINGE
SIDE
LOCK
SIDE
FULL CLOSURE
LOCK
SIDE
HINGE
SIDE
"(D)"
"(D)"
STANDARD
CLOSURE
"(A)"
"(G)"
"(B)"
"(A)"
LOCK
SIDE
"(D)"
STANDARD
CONSTRUCTION
"(F)"
"(G)"
"(A)"
LOCK
SIDE
"(D)"
"(B)"
"(D)"
PANIC BLOCKING
Note:
Shaded blocks are
extra-cost options.
FULLY BLOCKED
8/0 SMOOTH STAR AND FIBER CLASSIC BLOCKING OPTIONS
NOTE: FULLY BLOCKED NOT AVAILABLE IN FLUSH GLAZED.
"(C)"
"(C)"
"(C)"
"(L)"
"(K)"
"(C)"
"(C)"
STANDARD BLOCKING
"(K)"
"(K)"
PANIC PREP BLOCK
"(E)"
"(B)"
"(B)"
"(A)"
AND
“(H)"
"(A)"
AND
“(H)"
"(B)"
"(A)"
AND
“(H)"
CLOSURE BLOCK
"(J)"
"(J)"
"(F)"
"(A)"
AND
“(H)"
"(B)"
"(A)"
AND
“(H)"
"(B)"
HINGE
SIDE
HINGE
SIDE
LOCK
SIDE
LOCK
SIDE
"(D)"
LOCK
SIDE
HINGE
SIDE
HINGE
SIDE
"(D)"
STANDARD
CONSTRUCTION
LOCK
SIDE
HINGE LOCK
SIDE
SIDE
"(D)"
STANDARD
CLOSURE
"(D)" "(D)"
FULL CLOSURE
FULLY BLOCKED
PANIC BLOCKING
STEEL BLOCKING OPTIONS
NOTE: ONLY ONE STILE CAN BE FULLY BLOCKED, EITHER LOCK OR HINGE ON STEEL PRODUCT.
"(C)"
"(C)"
"(K)"
"(C)"
"(L)"
"(E)"
"(E)"
"(G)"
"(H)"
"(G)" "(B)"
"(B)"
"(K)"
"(F)"
"(K)"
"(C)"
"(E)"
"(E)"
"(H)"
"(J)"
"(G)"
"(J)"
"(H)"
"(G)"
"(H)"
"(G)"
"(B)"
"(A)"
"(A)"
"(C)"
"E"
"(E)"
"(H)"
"(H)"
"(B)"
"(C)"
"(K)"
"(A)"
"(B)"
"(A)" "(B)"
"(A)"
"(A)"
HINGE
SIDE
LOCK
SIDE
HINGE
SIDE
LOCK
SIDE
HINGE
SIDE
LOCK
SIDE
"(D)"
"(D)"
LOCK
SIDE
HINGE
SIDE
LOCK
SIDE
"(D)"
"(D)"
STANDARD
CLOSURE
STANDARD
CONSTRUCTION
HINGE
SIDE
PANIC BLOCKING
FULL CLOSURE
"(C)"
1.50”
"(C)"
"(L)"
"(K)"
"(E)"
"(J)"
"(A)"
"(B)"
"(B)"
"(A)"
"(A)"
"(B)"
"(B)"
"(A)"
FULLY BLOCKED
LOCK
"(D)"
Note:
See Chart for
Dimensions
on Next Page
"(C)"
"(K)"
LOCK
SIDE
"(D)"
FULLY BLOCKED
HINGE
CLASSIC CRAFT BLOCKING OPTIONS
"(C)"
HINGE
SIDE
"(F)"
"(A)"
"(B)"
HINGE
SIDE
LOCK
SIDE
"(D)"
STANDARD CONSTRUCTION
FOR NON-RADIUSABLE
CLASSIC-CRAFT
Shop 3
HINGE
SIDE
HINGE LOCK
SIDE
SIDE
"(D)"
STANDARD CONSTRUCTION
FOR RADIUSABLE & RUSTIC
CLASSIC-CRAFT
HINGE
SIDE
LOCK
SIDE
"(D)"
"(D)"
STANDARD CLOSURE FOR
NON-RADIUSABLE
CLASSIC-CRAFT
HINGE
SIDE
LOCK
SIDE
LOCK
SIDE
"(D)"
FULL CLOSURE FOR
NON-RADIUSABLE
CLASSIC-CRAFT
2014 (U1 REVISED)
PANIC BLOCKING FOR
NON-RADIUSABLE
CLASSIC-CRAFT
3.3
3.4
2014 (U1 REVISED)
8/0 U1 Flush Glazed and Molded Open Doors
Profiles And Traditions Steel
6/6 & 6/8 U1 Doors
7/0 U1 Doors
8/0 U1 Traditions Doors
6/6 & 6/8 U1 Doors
6/6 & 6/8 U1 Flush Glazed and Molded Open Doors
7/0 U1Doors
8/0 U1 Doors
8/0 U1 Flush Glazed and Molded Open Doors
Smooth Star
6/6 & 6/8 U1 Doors
6/6 & 6/8 U1 Flush Glazed and Molded Open Doors
7/0 U1 Doors
8/0 U1 Doors
1 3/32
1 3/32
1 3/32
1 3/32
1 5/32
1 3/32
3 15/16
1 3/32
3 15/16
1 5/32
1 1/4
1 1/4
6/8 U1 Fire Doors
8/0 U1 Fire Doors
Fiber Classic
3 7/8
3 31/32
6/8 U1 Arched & Radius Rustic & Canvas Doors
6/8 and 8/0 U1 Flush Glazed and Molded Open Doors
1 1/4
B
Hinge
Stile
Width
(Inches)
7/8
15/16
15/16
1 15/16
1 1/2
1 15/16
C
Top Rail
Height
(Inches)
7/8
15/16
15/16
1 15/16
D
Bottom Rail
Height
(Inches)
36
40
42
36
36
40
42
36
36
40
42
Not Available
12 1/2
12 1/2
12 1/2
Not Available
Not Available
12 1/2
12 1/2
Not Available
24
F
Panic Block
Length
(Inches)
Not Available
43 5/8
27 5/8
E
Lock & Panic Block
Location
(Inches)
H
Lock Block Width =
Lock Stile Width + Lock
Block Width
(Inches)
24
3 25/32
3 15/16
Not Required Wide Lock Stile
See Column "A"
12 1/2
3 15/32
2 3/8
2 3/8
3 15/16
Not Required Wide Lock Stile
See Column "A"
12 1/2
3 15/32
2 12/32
2 3/8
Not Available
HPC Filled
22 1/2
Not Required Wide Stiles
See Columns "A & B"
Not Required Wide Lock Stile
See Column "A"
G
Lock Block Length
(Inches)
3 25/32
2 3/8
3 15/32
3 15/32
2 3/8
3 4/8
3 15/32
3 7/8
J
Panic Block Width =
Hinge Stile +
Panic Block Width
(Inches)
24
L
Closure
Block Size
Width
(Inches)
3 7/8
Not Available
4 1/32
4 1/32
Not Available
Not Available
4 1/32
4 1/32
Not Available
24
28 5/8
28 5/8
28 5/8
28 5/8
Not Available Use Non-Radiusable
Door
Not Available
4 1/8
K
Closure Block Height =
Top Rail Height +
Closure Height
(Inches)
Door
Preparation
6/8 U1 Doors
6/8 U1 Rustic & Canvas Non-Radius
8/0 U1 Doors
8/0 U1 Rustic Non-Radius
Classic Craft
A
Lock
Stile
Width
(Inches)
Stile, Rail and Reinforcement Block
Sizes and Locations
Shop 3
90 Minute Positive Pressure Steel Fire
Door Reinforcement Sizes & Locations
Door
Preparation
DOOR
PREP
6”
4”
3/4”
21”
1-11/16”
3/4”
4-1/2”
16 GAUGE
STEEL PLATE
16 GAUGE
STEEL PLATE
6/8 43-31/32”
7/0 47-31/32”
16 GAUGE
STEEL PLATE
21”
11”
6”
LOCK
SIDE
HINGE
SIDE
2-3/4”
3/4”
4”
4-1/4”
COMPOSITE OR
WOOD LOCK BLOCK
*When panic reinforcement
is ordered.
(OPTIONAL WOOD BLOCK SHOWN)
16 GAUGE
STEEL PLATE
6”
3/4”
3/4”
4”
Shaded areas are extra-cost options.
Shop 3
2014 (U1 REVISED)
3.5
Door Slab Trimming
Door
Preparation
Maximum height and width trims for doors.
Standard
A
B
C
Top Rail Bottom Rail Hinge Stile
Doors a
Classic-Craft
1-1/4"
1-1/4"
Fiber-Classic
1/4"
1/4"
Smooth-Star
1/4"
1/4"
Steel Doors
1/4"
1/4"
a
Standard doors requiring structural product
certification cannot be trimmed.
b
1/32" b
1/32"
1/32"
1/16"
approval or
C
Hinge
Stile
D
Lock Stile
1/32"
1/32"
1/32"
1/16"
b
A
Top
Rail
Inspect corners to verify hardwood thickness before trimming.
A
Top Rail
1"
N/A
N/A
Impact
Doors
Classic-Craft
Fiber-Classic
Smooth-Star
Steel Doors
B
C
Bottom Rail Hinge Stile
1"
N/A
N/A
N/A
N/A
N/A
D
Lock
Stile
D
Lock Stile
N/A
N/A
N/A
c
N/A
N/A
N/A
N/A
Standard steel doors are impact-rated, but cannot be trimmed
when requiring an impact product approval, see re-sizing section.
c
Fire Rated
Doors
Classic-Craft
A
Top Rail
B
C
Bottom Rail Hinge Stile
D
Lock Stile
d
N/A
3/4"
1/32"
1/32"
Fiber-Classic
d
N/A
1/4"
1/32"
1/32"
Smooth-Star
d
N/A
1/4"
1/32"
1/32"
N/A
N/A
1/16"
1/16"
Steel Doors
e
B
Bottom
Rail
d
Fiberglass 20-minute positive pressure fire doors can only be
trimmed by Warnock-Hersey or NAMI certified re-machiners.
e
Standard wood-edge steel doors may be fire-rated (if appropriately
labeled), but cannot be trimmed in height when being used as a fire
door, see re-sizing section. 90-minute steel edge fire doors cannot
be trimmed, see 90-minute fire door re-sizing section.
Trim Slab to Width
- Set planer cutting depth.
- Plane edges of slab.
- Sand smooth if required.
- Paint with primer if required to match
original finish.
Trim Slab to Height
- Measure and mark door slab.
- Cut along line with saw, using
carbide-tipped blade. If available,
use panel saw.
- Touch up edges with a rasp or
sandpaper.
- Trimming the bottom rail may
prevent the kerf door bottom from
fitting properly. A replacement
staple-on door bottom may need
to be used.
3.6
2014 (U1 REVISED)
Shop 3
Door Slab Resizing
Door Slab Resizing Beyond Maximum Trimming Limits
Door
Preparation
STOP:
Fiberglass impact doors and 20-minute fiberglass fire doors cannot be re-sized
beyond maximum trimming limits. For 90-minute steel edge fire doors, see
90-minute fire door slab re-sizing section.
Height Resizing
Note:
A standard door can be cut down to any size if it is aesthetically acceptable, the following
procedure for re-railing is followed, and it conforms to the applicable code requirements.
Flush doors and paneled doors may be re-railed. Any height re-sizing beyond maximum
trim limits requires rail replacement. 20-minute steel fire doors can only be resized by a
Warnock Hersey certified re-machiner.
Width Resizing
Doors cannot be edge-trimmed beyond the limits listed in SHOP 3 - Door Slab Trimming
Saw Slab to Length
Measure and mark door slab.
Cut along line with saw, using
carbide-tipped blade. If
available, use panel saw.
Touch up edges with rasp or
sandpaper.
Note: For 20-minute steel fire
doors, a maximum of 6” may be
removed from the bottom of
the door.
Mark for New Rail Pocket
Equal
Use new rail as a pattern.
Center rail against cut end
of door slab.
Equal
Scribe at rail ends to mark limits
of cut for rail pocket.
Scribe line
each end
Shop 3
2014 (U1 REVISED)
3.7
Door Slab Resizing
Cut New Rail Pocket
Scribe mark
Door
Preparation
Remove core material to desired depth
using wire brush on a drill.
Cut to scribe marks at ends.
Cut flush to inside skin faces.
Clean Up New Rail Pocket and Test-Fit
Clean up corners and/or fiberglass
skin ribs with a chisel.
Scrape skin faces clean to ensure
a good adhesive bond.
Test-fit rail in pocket.
3.8
2014 (U1 REVISED)
Shop 3
Door Slab Resizing
Mix Adhesive
Door
Preparation
Use a fast-setting epoxy.
Mix thoroughly before applying to
door skins.
Note: For 20-minute steel fire doors,
only adhesive(s) specified in the
applicable fire door listing report
may be used.
Apply Adhesive
Fully coat inside skin surfaces of rail pocket.
Insert Rail
Use plain, no-kerf rails at top of door, or
kerfed rail with kerfed edge pointing
inward (not showing).
At bottom end, place rail in pocket with
kerfed edge facing out.
Note: For 20-minute steel fire doors,
only the bottom rail may be replaced.
The replacement rail must conform to
the specifications in the applicable
fire door listing report.
Shop 3
2014 (U1 REVISED)
3.9
Door Slab Resizing
Clamp Assembly
Door
Preparation
Clamp to ensure uniform pressure.
Use pad boards to protect slab skins.
Allow to dry per adhesive instructions.
Bottom rail with
2 clamps shown
3.10
2014 (U1 REVISED)
Shop 3
90 Minute Fire Door Slab Resizing
CAUTION:
Only shops licensed by Warnock-Hersey as fire door machiners may perform this resizing
procedure. These instructions are for reference only. Please refer to the current
Warnock-Hersey machining report for the currently approved procedure.
Shop 3
2014 (U1 REVISED)
3.11
Door
Preparation
Slab Repair
Stile Chips
Door
Preparation
Fill Chips and Sand Smooth
Fill minor cosmetic damage to wood
stiles with a hardening type wood putty.
File and sand smooth.
Reprime Area Using Touch-up Paint
3.12
2014 (U1 REVISED)
Shop 3
Slab Repair
Steel Door Dent Repair
Door
Preparation
Clean and Roughen Surface
Clean surface surrounding dent.
Roughen using 100 grit sandpaper.
If possible, do not sand through
the existing factory-applied primer.
Fill Dent
Fill dent using Therma-Tru Dent Repair
Kit, (Part Number: MS00DRK), or an automotive
body-filler compound.
Smooth using a wide blade putty knife.
Overfill to account for shrinkage and sanding.
Sand Dent Repair
Sand repair, using a large sanding block
or orbital power sander, with 220 grit
sandpaper.
Shop 3
2014 (U1 REVISED)
3.13
Slab Repair
Steel Door Dent Repair - Cont.
Reprime Repair Area(s)
Door
Preparation
If bare metal was exposed, paint
entire repair area with a primer
containing rust inhibitors.
Reprime repaired area using
Therma-Tru touch-up primer. If a
rust inhibiting primer was used, let
dry thoroughly before applying
Therma-Tru touch-up primer.
THERMA-TRU TOUCH-UP PRIMERS
Description
Part Number
Classic-Craft and Fiber-Classic Primer for Buff skins
MSCCAB-01
Classic-Craft Mahogany Primer for Rose skins
MSCCMAB
Smooth-Star Primer
MSWHSABP-03
Steel White Primer
MSWHABP-01
Steel Edge Door Primer
MSWHSED
Steel Frame Primer
MSWHAF2
Classic-Craft, Fiber-Classic and Smooth-Star Skin Repair
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Therma-Tru does not recommend any other repair procedures for composite doors.
3.14
2014 (U1 REVISED)
Shop 3
Hinge Preparation
(Except 90 Minute Steel Fire Door)
Mark top of hinge mortises.
(Index from top edge of door)
UNDERSIZE
DIMENSIONS FROM TOP EDGE OF DOOR TO
HINGE LOCATIONS
DOOR HEIGHT
Door
APPLIED TO HINGE 1 HINGE 2 HINGE 3 HINGE 4
Preparation
6/6
6/8
8/0
8.250"
38.000"
67.750"
N/A
33.250"
58.750"
83.750"
ADJUSTABLE HINGE
HINGE LOCATION (TOP DOWN)
DESCRIPTION
6/8 DOOR
8/0 DOOR
Top Edge
HINGE 1
8.525”
5.431”
HINGE 2
37.775”
30.931”
HINGE 3
67.025”
56.431”
HINGE 4
N/A
81.931”
Hinge
1
Hinge
2
Hinge
3
Hinge
4
Shop 3
2014 (U1 REVISED)
3.15
Hinge Preparation
Arch Top Door
Mark bottom of hinge mortises.
Door
Preparation
(Index from bottom edge of door)
DESCRIPTION
ARCH
ARCH
DOOR SLAB
HINGE LOCATIONS
HEIGHT SIZE HINGE 1 HINGE 2 HINGE 3 HINGE 4
6/8
U1
8.157" 35.594" 63.032"
N/A
8/0
U1
9.282" 32.532" 55.782" 79.032"
Hinge
4
Hinge
3
Hinge
2
Hinge
1
3.16
2014 (U1 REVISED)
Shop 3
Hinge Preparation
Radius Top Door
Mark bottom of hinge mortises.
(Index from bottom edge of door)
DESCRIPTION
3/0 X 6/8
RADIUS
3/6 X 6/8
RADIUS
3/0 X 8/0
RADIUS
3/6 X 8/0
RADIUS
Door
Preparation
HINGE LOCATIONS
DOOR SLAB
HEIGHT SIZE HINGE 1 HINGE 2 HINGE 3 HINGE 4
6/8
U1
8.157"
31.282"
54.407"
6/8
U1
7.157"
29.282"
51.407"
8/0
U1
29.657"
50.032"
70.407"
28.657"
48.032"
67.407"
N/A
9.282"
8/0
U1
Hinge
4
Hinge
3
Hinge
2
Hinge
1
Shop 3
2014 (U1 REVISED)
3.17
Hinge Preparation
(Except 90 Minute Steel Fire Door)
Pass-Through
Door
Preparation
Mark and Cut Mortises
Use a special-purpose machine or a
router and template.
4.015”
Adjustable
.112”
R .625”
3.654”
.354”
.625”
Deep
Door
Edge
Full Mortise
CAUTION:
Full mortises require pilot holes only
if door has hardwood stiles. Refer to
SHOP 3 - Hinge Installation,
for instructions.
R .625”
or
R.250”
4.015”
.112”
1.375”
3.18
2014 (U1 REVISED)
Shop 3
Lock Preparation
(Except 90 Minute Steel Fire Door)
NOTE:
See 90-Minute Steel
Fire Door Lock Preparation.
Door
Preparation
Mark for Lock Preparation
Preparation shown is for standard cylindrical lock sets.
For mortise locks and other types use manufacturer's
templates and instructions.
Top
Edge
CAUTION:
Due to stile width and lite placement, some
door styles have restrictions on lock crossbore
and backset. Using the DOOR STYLE
manual, (paperback or web site), see if
restrictions apply. Deadbolt locations
and sizes vary.
6/6 & 6/8 - 43.969”
8/0 - 59.969”
NOTE:
If cutting second prep for deadbolt, spacing should be 7”
maximum for Fiber-Classic, Smooth-Star and Steel doors.
No restriction applies for Classic-Craft doors.
Deadbolt
Spacing
(see note
at left)
Lock
Center
Crossbore
Diameter
2.125”
1.016”
2.266”
Backset
2.375” or 2.750”
Edge bore
Diameter
1”
.172” Deep
at center
.250” R.
(Mortise using
a .500” dia. bit.)
Shop 3
2014 (U1 REVISED)
3.19
Lock Preparation
(Except 90 Minute Steel Fire Door)
Drill Crossbore When Door Machine Is Not Available
Door
Preparation
Bore through half of door thickness until pilot pierces other side.
CAUTION:
Do not bore completely through
to other side of door.
Flip door over.
Align drill with pilot hole
and complete boring.
3.20
2014 (U1 REVISED)
Shop 3
Lock Preparation
90 Minute Steel Fire Door
Door
Preparation
Mark for Lock Preparation
Preparation shown is for standard cylindrical lock sets.
For mortise locks and other types use manufacturer's
templates and instructions.
Top
Edge
CAUTION:
Due to stile width and lite placement, some
door styles have restrictions on lock crossbore
and backset. Using the DOOR STYLE
manual, (paperback or web site), see if
restrictions apply. Deadbolt locations
and sizes vary.
6/8: 43.969”
7/0: 47.969”
Lock
4” or 5.50” Center
Crossbore
Diameter
2.125”
1.155”
2.281”
Backset
2.375” or 2.750”
Shop 3
2014 (U1 REVISED)
3.21
Lock Preparation
90 Minute Steel Fire Door
CAUTION:
Only shops licensed as fire door machiners may perform this lock preparation.
Door
Preparation
Drill Crossbore When Door Machine Is Not Available
Bore through half of door thickness until pilot pierces other side.
CAUTION:
Do not bore completely through
to other side of door.
Flip door over.
Align drill with pilot hole
and complete boring.
3.22
2014 (U1 REVISED)
Shop 3
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Multipoint Lock Preparation
Door
Preparation
Preparation shown is for Therma-Tru multipoint lock
set door preparation only. Jamb preparation is shown
in individual unit preparation sections. Use this as a
reference guide along with the manufacturer’s
templates and instructions.
Note:
Multi-Point Lock Systems recommended only
for Fiberglass Products including: Classic-Craft,
Fiber-Classic, and Smooth-Star.
Handle
Height
Deadbolt
Spacing
(see note
at left)
6/6 - 33.452”
6/8, 8/0 - 36.000”
Crossbore
Diameter
.500"
Crossbore
Slot
.255" R
1.750" 45mm
2.344" 60mm
Crossbore
Diameter
.500”
1.750” 45mm
2.344” 60mm
2.604"
2.756”
Handle
Height
1.006"
.846”
3.781"
Crossbore
Slot
.406" R
Handle
Height
4.411"
5.281"
Crossbore
Slot
.255" R
Multipoint Lock Preparation
Shop 3
Dummy Lock Preparation
2014 (U1 REVISED)
3.23
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Eurogroove Preparation
Door
Preparation
Set Router Bit Depth &
Adjust Guide Fence
Set the bit depth using the manufacturer’s guide that
came with the router. The depth of the route should
be 12mm (roughly 15/32”).
Note: Test the route depth on a scrap piece of wood.
Adjust the guide fence so that the assembly can slide
down the entire length of the door.
Adjustable
Edge
Note: If binding occurs, readjust the fence at the
thickest section of the door.
Fixed Edge
Door Lock
Edge
Secure Door on Edge & Apply
Router & Guide Fixture
Set assembly on the door panel and move it until the
bit reaches the door edge. Move the assembly away
from the door edge so that the bit is not in contact
when the router is started.
CAUTION: The fixed edge guide for
the Eurogroove Router and the fixed edge of the
Gear & Handle Mortise Jig must be located on the
same side of the door during the preparation. Failure
to do so could result in off-center relationship of
gear mortise and eurogroove.
Cut Eurogroove
NOTE: For best results, set the router at
maximum RPM.
Route the entire length of the door edge.
Apply constant pressure against the fixed
edge of the router fence for best results.
Remove the sawdust after the cut is
complete.
3.24
2014 (U1 REVISED)
Shop 3
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Gear Mortise Preparation
Apply Cross Mortise Fixture
Door
Preparation
Set the cross mortise jig on the edge of the door
and slide up until the lock height setting bolt
has contacted the bottom edge of the panel.
Carefully tighten the adjustment knob enough
to secure the jig to the panel.
NOTE: Over tightening can cause the width of
the mortise pocket to be cut improperly.
NOTE: Be sure the jig is flat against the edge
of the panel and tight against the bottom to
provide proper placement of the handle
mechanism.
Set Up Plunge Router
Set the depth of cut using the manufacturer’s
guide that came with the plunge router. The
depth of the route should be 64mm (approximately 2-9/16” for 45mm & 3-7/32” for 60mm)
using a 1/2”cut by 5-1/2” long bit with a 3/16”
collar.
Plunge
Router
1/2”x5-1/2” Bit
Cut Gear Mortise
CAUTION: The router bit will
extend past the base of the router.
Make sure the router is sitting firmly
in the jig before starting the router.
Let the router come to a complete
stop before removing from the jig.
Slide the bit into the opening on the jig and
make cut using several passes along the guide
to obtain the proper depth.
Note: It is recommended to cut 1/4” - 1/2”
each pass.
Shop 3
2014 (U1 REVISED)
3.25
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Door
Preparation
Manual Tongue Bolt System
The Manual Tongue Bolt system is used for all single and sidelite unit configurations. This system
requires a lower gear and a top extension only. The faceplate of these parts is trimmable up to the
screw hole above or below the tongue mechanism.
Tongue Bolt Trimming Specifications
Door Slab Height
Gear Part Number
Maximum Trim
(6/6) 76.75" - 64.25"
(6/8) 79.25" - 66.75"
(7/0) 83.25" - 70.75"
(8/0) 95.25" - 84.25"
MPDGARTP
MPDGART
MPDGART
MPDGART
2"
4.5"
4.5"
4.5"
Top Extension
Part Number
MPARTTE68
MPARTTE68
MPARTT370
MPARTTE80
Maximum Trim
8"
8"
8"
6.5"
Notes:
1. Trimming of bottom gear will change the handle height on door. Determine the desired handle height
before machinging for lockset.
2. Trimming of top extension will not change handle height on door.
3. The extensions can be trimmed as desired as long as there is a screw hole left beyond the tongue
mechanism for secure mounting.
3.26
2014 (U1 REVISED)
Shop 3
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Both the Shootbolt System and the Tongue Bolt systems were designed to be easily modified in height
for use with cut down doors. Therma-Tru multi-point lock hardware is made from a weather resistant
300 series stainless steel, so the number of parts you need to modify for production will determine
what methods you will use to trim them with.
Very Low Volume
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Ɣ+DFN6DZ&DUERQVWHHOILQHWRRWKEODGH
Ɣ*ULQGLQJ:KHHO
Moderate Volume
Ɣ%DQG6DZ+LJK&DUERQVWHHOILQHWRRWKEODGH
Manual Shootbolt System - Variable Height Option
7KH9DULDEOH+HLJKW6KRRWEROW6\VWHPLVXVHGSULPDULO\IRUGRXEOHGRRUXQLWV7KLVV\VWHPUHTXLUHV
a middle extension (MPMESB) and a trimmable top extension in addition to a standard Shootbolt
system gear. The trimmable top extensions and their usage by door height are listed below.
Shootbolt System Trimmable Top Extensions
Door Slab
76.61" 80.55"
82.52" - 86.46"
88.43" - 92.36"
91.38" - 95.31"
Part Number
MPTE8611
MPTE8619
MPTE8627
MPTE8631
Extension Length
15.75"
21.56"
27.56"
30.51"
Maximum Trim
3.94"
3.94"
3.94"
3.94"
Notes:
:KHQFXWWLQJWKHWRS6KRRWEROWH[WHQVLRQWKHIDFHSODWHPXVWEHFXWWRWKHH[DFWOHQJWKDVWKHGLVWDQFH
from the top of the door to the middle extension faceplate for a precise connection seam.
2. Make sure to have at least 1.24 inches of serrations left on the drive rail to make a good connection.
3. Be sure to have the end of the drive rail pulled even with the faceplate before cutting the top extension.
See illustration below.
Shop 3
2014 (U1 REVISED)
3.27
Door
Preparation
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Trim Set Preparation
Door
Preparation
Cut Trim Set Holes
Using the same cross mortise jig set up, place
the door laying flat on a table to ease this
portion. Reset the plunge router bit to allow
the guide to rest completely flat on the face
of the jig and route all holes through the face
of both sides of the door panel.
CAUTION: The router bit will
extend past the base of the router.
Make sure the router is sitting
firmly in the jig before starting
the router. Let the router come
to a complete stop before
removing from the jig.
3.28
2014 (U1 REVISED)
Shop 3
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Step 1- Sidelite Handle/Mortise Jig for the Venting S/L units
Door
Preparation
Tools Required:
Plunge router with 1/2” bit and
13/16” collar (Provided in door kit)
Drill bit 7/16”
Drill bit stop (provided)
1/8” Hex head wrench
Power Tool Notes:
Remember to always follow the safety and operation instructions of the equipment
manufacturers.
Using the information given below, determine the handle position. Place the pin in the hole at the bottom that
is marked with the correct handle height. Attach the wing nut to the pin to secure it in place.
Set the router plunge depth to 50.5mm (1.988”).
Slide the drill stop over the 7/16” drill bit and then rest the bit on the top of the jig. The bit should extend to a
depth of 31.75mm (1.250”) or 1-1/4” into the sidelite. Tighten the stop with a 1/8” hex head wrench. Adjust if
Note: With a sidelite system the thumb turn is on the interior side only. As a safeguard the jig has this instruction etched on the top. Drill from the interior side only.
Slide the jig over the lock stile of the sidelite such that the locator pin is resting against the bottom rail.
to the panel. Do not over tighten.
Using the 7/16” drill bit with drill stop, bore the 3 handle holes on the inside surface of the door.
Do not drill all the way through the sidelite.
Plunge route the top slot to a depth of 33.5mm (1.3”) or 1-15/16”. For best results, use multiple passes to
avoid chipping out the wood.
Remove jig, clean out the saw dust, and install multipoint locking hardware and thumbturn.
UNIT SIZE
6/6
6/8, 8/0
Shop 3
HANDLE
HEIGHT
33.452”
36.000“
2014 (U1 REVISED)
3.29
Multipoint Lock Preparation
(Except Fire & Steel Doors)
Step 2 - Sidelite Eurogroove Machining
Door
Preparation
Tools Required:
Eurogroove router
(Provided in door kit)
Eurogroove Stops
Power Tool Notes:
Remember to always follow the safety and operation instructions of the equipment
manufacturers
Using the information provided below, determine the distance from each end that the Eurogroove
should stop.
For lengths less than 5”, the wing nut is removed from the two piece jig, which is then clamped to
the top surface of the sidelite. The two adjustable nuts are then used for the stop locations.
For lengths greater than 5”, place the pin with the wing nut in the hole that corresponds with the
desired distance. The one piece jig is then clamped to the lock side of the sidelite.
Place the router on the sidelite stile with the bit extending into the hole machined in Step 1.
Then machine the Eurogroove, stopping the router when the base plate hits each stop
UNIT
SIZE
6/6
6/8
8/0
3.30
BOTTOM
STOP
12.562”
15.110”
15.110”
TOP
STOP
2.394”
2.191”
15.191”
2014 (U1 REVISED)
Shop 3
Classic-Craft Panel Installation
Note: DP300CC used on CC30300 only. DP300CCM used on CCM30300. Temperature range for
optimal tape adhesion is 70° to 100°F. Minimum suggested application temperature is 50°F.
Door
Preparation
1. Moisten a clean cloth with 70%
Isopropyl Alcohol. Wipe flat
surface around entire perimeter
of opening. Allow to dry.
Not preparing door will result
in poor panel adhesion.
Clean flat
surface all
around
perimeter
with alcohol
2. Remove carrier backing
from tape on back of panels.
Carrier backing
3. Position panel in opening
and press down firmly
around outside edges.
Press here with
approximately 10 psi.
Door
Panel
Insulating Foam
Shop 3
2014 (U1 REVISED)
3.31
Classic-Craft Panel Installation
4. Flip door over.
Door
Preparation
5. Apply two (2) 1/4” - 3/8” beads of structural adhesive to back of panel.
Adhesive
6. Remove backing from tape,
position panel, and press
firmly into place.
Press here with
approximately 10 psi.
Door
Panel
Insulating Foam
Door
Preparation
3.32
2014 (U1 REVISED)
Shop 3
Doorlite and Panel Preparation
Select the correct template to match the door style. Refer to SHOP 17.
CAUTION:
If door was resized, template use may be affected. Template location is referenced from the
top of the door and embossed pattern adjustments may be necessary. Template may need to
be centered from side-to-side.
Align Template
Template
Place template on door slab.
Align with edge
of hinge stile
Align template with top and edges of door
using corners or notches in template.
Align with top
of door slab
Door Slab
Clamp Template to Door
Clamp mechanism and door support table
shown here are typical for Ruvo/Triad
door cutout machines.
Use a wood pad
to prevent damaging
door.
Shop 3
2014 (U1 REVISED)
3.33
Door
Preparation
Doorlite and Panel Preparation
Cut Slab for Doorlites or Panels
Door
Preparation
All templates are designed for use with standard
cutout machines. Template openings are offset
exactly 1/2” from cutout edges.
Check templates periodically for wear and replace
when required. Refer to Door Styles Manual for
cutout size specifications.
Modify heavily used templates by adding metal
or wear-resistant plastic to edges. Relieve
template edges to allow for wear plate thickness.
3.34
2014 (U1 REVISED)
Shop 3
Doorlite & Designline
Panel Installation
Always place door in HORIZONTAL position before removing lite
or panel.
Separate Lite or Panel Frames
Remove screws or staples to separate
lite or panel frames.
Apply Glazing Tape to Entire Perimeter
of Exterior Frame
If not factory applied, apply foam
glazing tape (Part No. RPGLZTP).
DO NOT stretch.
Overlap at corners.
Press on lightly with fingers. Then with
a roller tool, fully bond gasket using firm
pressure.
Position Lite/Panel into
Opening
Interior side
Place lites and panels against bottom
edge of cutouts to prevent shifting.
Center lites and panels in cutout,
side-to-side
Exterior lite frame
(half with glass)
.
Exterior panel
Shop 3
2014 (U1 REVISED)
3.35
Door
Preparation
Doorlite & Designline
Panel Installation
Interior lite frame/panel
Door
Preparation
Position Interior Sides
of Frames and Panels
Ensure correct alignment of
screw bosses.
Align
bosses
.
NOTE: When installing multiple lites, use a straight edge to
check alignment of lites before securing in place.
Select the Right Screw
Use the correct screw with the appropriate lite frame. (Fasteners are shown actual size.)
For this lite
Use this fastener
Classic-Craft Doorlite
(for molded opening)
Part # SCSMC750
Classic-Craft Doorlite
(for surface mount)
Fiber-Classic Doorlite
Smooth-Star Doorlite
Steel Doorlite
3.36
2014 (U1 REVISED)
Part # SCSMCL
Part # SCDL000
Shop 3
Doorlite & Designline
Panel Installation
Select the Right Screw
Use the correct screw with the appropriate lite frame. (Fasteners are shown actual size.)
For this lite
Door
Preparation
Use this fastener
Brass Finish
Entire Screw
Fiber-Classic Doorlite
without Screw Bosses
Part # RPSCFCLDL
Fiber-Classic, Smooth-Star
and Steel Doorlites
Part # SCDL000
White Painted Head
Smooth-Star and
Steel Doorlites
without Screw Bosses
For this panel
Part # RPSCLDL
Use this fastener
Fiber-Classic Designline Panel
Part # SCDL000
Shop 3
2014 (U1 REVISED)
3.37
Doorlite & Designline
Panel Installation
Select the Right Screw
Door
Preparation
Use the correct screw with the appropriate lite frame. (Fasteners are shown actual size.)
For this lite
Use this fasteners
Wrought Iron Doorlite
Impact Doorlite
3.38
2014 (U1 REVISED)
Part # CCRSCREW
Part # SCCCA150
Shop 3
Doorlite & Designline
Panel Installation
Adjust Screwgun Torque
MAXIMUM AND MINIMUM TORQUE SETTINGS
CAUTION:
DO NOT exceed
maximum torque.
Doorlite
Door
Preparation
Torque
(in-lbs)
Classic-Craft
9-12
Classic-Craft Wrought Iron & Impact
67-70
Fiber-Classic, Smooth-Star & Steel
12-14
Drive Screws with #2
Phillips Bit
Ensure frame edges are well-seated.
NOTE:
Doorlites may be shipped with only
enough screws for safe transport.
Additional screws may be made up
from bulk supply.
Shop 3
2014 (U1 REVISED)
3.39
Impact Doorlite Installation
Interior Frame
Door
Preparation
Door Shop
Applied
1/4” Bead
Dow 995
Structural Sealant
Sna p-in Screw
Chann e l Cover
2
1
# 10 x 1-1/2 ”
Panhead Screw
Laminated Glass
Door
Exterior Fram e
SCREW CHANNEL COVERS:
(1) Place short side of miter to inner edge of frame.
(2) Rotate cover down snapping long side of miter into place.
NOTE: Fine tuning of lengths may be needed to acquire optimal fit.
The interior frame only must be wet glazed to door slab and insulated glass
unit as shown with Dow 995 structural sealant. Minimum 1/4” beads are
required.
Assemble with #10 x 1-1/2” pan head screws. Screws to be tightened at 70
in. lbs.
NOTE: Laminated glass must be facing the interior frame and the structural
sealant.
3.40
2014 (U1 REVISED)
Shop 3
Hinge Installation
Use the Correct Leaf
Door
Preparation
Leaves applied to door have 2 knuckles.
Leaves applied to jamb have 3 knuckles.
2-Knuckle
Door Leaf
With Tabs
3-Knuckle
Jamb Leaf
Pass-Through Mortise
Align and Install Hinges
Place tabs firmly against door skin.
Fasten 2-knuckle hinge leaves with proper
screws.
Place hinge
tabs firmly
against door.
#10 x 1”
Phillips flat
head screw
Part # RPSCDRB-XX
Full Mortise
Align and Install Hinges
Use mortises to properly
align 2-knuckle hinge leaves.
Drill 1/8” diameter pilot
holes if mounting hinges to
hardwood stiles.
Fasten 2-knuckle hinge
leaves with proper screws.
Pilot holes
Required for
hardwood stiles
(Classic-Craft only)
#10 x 1”
Phillips flat
Head screw
Part # RPSCDRB-XX
Shop 3
2014 (U1 REVISED)
3.41
Hinge Installation
Adjustable Hinges
Door
Preparation
Required Tools
1. A 3/16” hex wrench is required.
2. A small flat head screwdriver is required.
3. A plastic putty knife is recommended to prevent
damage to hinge finish.
There are two types of HOPPE Adjustable Hinges
on each door panel:
1. Set Hinge : one per panel. The set hinge
provides ± 0.12” vertical adjustment.
2. Guide Hinge : Two or three per panel. The guide
hinges provide ± 0.12” horizontal adjustment.
The two Guide Hinges go in top and bottom
locations with the Set Hinge in the center. For 8’
door the Set Hinge is located second from top of
door. Refer to Figure 2.
Guide Hinge Shown:
Assembly Information
1. Insert the thick side of the hinge into the hinge
mortise on the door.
2. Pre-drill 3/32” diameter pilot holes through hinge
holes.
3. Fasten with (4) #8 x 1-1/4” flat head screws refer
to Figure 1.
4. Place hinges into hinge mortise on the frame.
5. Seat hinge to back of machined hinge pocket.
6. Fasten with (2) #10 x 3/4” flat head screws in the
middle of each hinge.
Fasten the top & bottom holes with (2) 2-1/2” flat
head screws
Figure 1
Set Hinge
Vertical
Adjustment
(Under Finial Cap)
Guide Hinge
Horizontal
Adjustment
Adjustable Hinge Placement on Door
Guide
Guide
Set
Set
Guide
Guide
Guide
7/10 to 8/0
height doors
6/6 to 7/0
height doors
Vertical Adjustment (Set Hinge)
With the door closed or open
1. Remove the press-fit Finial Cap from the
bottom of the Set Hinge to expose the
adjustment screw. Use the small
screwdriver for Set Hinges featuring a
plastic Finial Cap. A plastic putty knife is
recommended for Set Hinges featuring a
brass Finial Cap.
2. Insert the hex wrench into the bottom of
the Set Hinge. Turn the screw clockwise to
raise the panel and counterclockwise to
lower the panel.
3. Reinstall the Finial Cap.
Horizontal Adjustment (Guide Hinge)
The door must be open to access the
adjustment screw.
1. Insert a 3/16” hex wrench into the
horizontal adjustment screw.
2. Turn clockwise to decrease the margin
and counterclockwise to increase the
margin on the hinge side.
Figure 2
3.42
2014 (U1 REVISED)
Shop 3
Hinge Installation
Surface-Mounted
(90-Minute Fire Door)
Section Cut for Clarity
#12-24 x 1/2”
Self Tapping
Screws
Door
Preparation
Align and Install Hinges
Use pilot holes to align
2-knuckle hinge leaves.
Seam
Fasten 2-knuckle hinge
leaves with proper screws.
Considerations for Assembled Hinges
Right-hand
application
shown
Riveted-pin hinges have locating tabs. Fasten to
slabs using same method as for unassembled
hinges, placing tabs against door face to locate hinge.
Right-hand
application
shown
Rotate to
opposite
side for
left-hand
application
Square leaf
fastens to
door
Riveted Pin Hinge
with Locating Tabs
Self- Aligning
Ball-Bearing Hinge
Right-hand
application shown
Hex adjustment
hole - left hand
Rotate to opposite
side for left-hand
application
Leaf with “UL”
logo fastens
to jamb
Hex adjustment
hole - right hand
Spring Hinge
For wood-edged doors with pass-through
hinge mortises, take care to place correct
leaf on door edge, and fasten at correct
backset, for alignment. (Backset is 1-3/8”)
To apply these hinges to wood-edged doors, use a
template and mark screws or bore 3/32” diameter
pilot holes.
A standard hinge leaf with locating tabs can also
be used as a template, if a vix-bit is used to center
the pilot holes in the centers of the hinge holes.
If assembled hinges are used, fastening door slabs to frames will require that the slabs be first
fastened to loose hinge jambs, with the rest of the frame and sill then being built around the slab.
Shop 3
2014 (U1 REVISED)
3.43
Door Bottom Selection & Installation
Select Door Bottom
Compatible sill types:
Any Composite Adjustable, Hardwood Adjustable,
or Basic Composite Adjustable Inswing Sills.
Door
Preparation
Dual Bulbed Kerf-Applied
Door Bottom DBDB300
Any Composite Adjustable, Hardwood Adjustable,
or Basic Composite Adjustable Inswing Sills.
Kerfless
Door Bottom RPDBDB300T
Basic Fixed Sill
Moderate Climate Sill
Expandable Steel Frame Sill (Inswing & Outswing)
Kerf-Applied
Door Bottom DB30094
Any sill
Public Access Sill
Primarily used as a replacement door bottom
Sweep/Replacement
Door Bottom DB30SWP
Used on cutdown doors when kerfs are trimmed
away.
Public Access Sill
Standard Adjusta-Fit 2
Adjusta-Fit 2 Steel Frame Sill
Fire Door Bottom TSA30
(Recommended)
Outswing Sills with exception of Composite Fixed
Outswing Kerf-Applied
Door Bottom DB30OS99
3.44
2014 (U1 REVISED)
Shop 3
Door Bottom Selection & Installation
CAUTION:
Outswing units with bumper sills
do not require door bottoms.
Apply sealant as shown to both ends of door
bottom.
Kerf Door Bottoms
Caulk and Fasten Door Bottom
Center door bottom and press into rail kerfs.
Select a sealant (Elastomeric or Polyurethane)
that provides excellent adhesion to both plastic
and wood.
Fasten ends of door bottom with (2)
1/4” or 1/2” crown x 3/4” or 7/8” staple
on each end.
Interior
side
of
door
Interior
side
of
door
Sealant
Sealant
1/4” or 1/2”
crown x 3/4”
or 7/8” staple
1/4” or 1/2”
crown x 3/4”
or 7/8” staple
‘90-Minute Fire Door’ Door Bottom
Door
Interior
Fasten Door Bottom
Slide door bottom between door and sill. Align at
ends and against inside face with lip. Screw door
bottom in place with (5) # 8 x 1/2 ” self piercing spear
tip screws beginning in the center and working out
to ends.
Door/Sill
Gap
Fig 1.1
Shop 3
2014 (U1 REVISED)
3.45
Door
Preparation
Door Bottom Selection & Installation
Sweep/Replacement Door Bottom
Door
Preparation
Fill Kerfs with Sealant
Fill kerfs
Fill kerfs in bottom rail with sealant
(Elastomeric or Polyurethane) if working
with trimmed door and shallow kerfs.
Caulk Sweep/Replacement Door Bottom
Select a sealant (Elastomeric or Polyurethane)
that provides excellent adhesion to both plastic
and wood.
Caulk around
Entire edge and
along center.
Apply bead of sealant (Elastomeric or Polyurethane)
to entire edge and center of the door.
Fasten Door Bottom
Place door bottom against rail.
Align at ends and against inside face
with lip.
Staple in place, beginning at center.
1/4” or 1/2” crown x
3/4” or 7/8”
staple
Lip
Work toward each end and fasten as
shown. Press flat to avoid scalloping.
Staple twice at each end as shown.
3”
3.46
2014 (U1 REVISED)
1”
Shop 3
Grille Installation
NOTE: Wood Grilles are for internal use only.
BTS
FLUSH GLAZED
Part # RPWGMC2
Part # RPFGGC
Grilles come complete with clips.
Door
Preparation
CC
Part # RPCGC
SPRING STEEL CLIPS
Position Clips
Locate clips on vertical sides of frames
4” maximum from each corner and at
center grille bar locations.
4” maximum
from corner
Center
Grille Bar
Locations
4” maximum
from corner
Installation for Lite Frames
Interior Lite
Frame
Install Clips
Doorlite
Screw
Loosen doorlite screws slightly.
Slide flat side of clips under
interior side of doorlite frame.
Bend slightly to
tighten fit with
grille if necessary.
Retighten screws.
Grille Clip
Shop 3
2014 (U1 REVISED)
3.47
Grille Installation
Installation for Flush-Glazed Doors
Door
Preparation
To assure proper installation, carefully remove any excess sealant at glass
edge before installing grille clips.
Insert steel spring clips between stop and glass at the locations shown.
AVOID PUTTING CLIPS IN LINE WITH MUNTINS HORIZONTAL
AND VERTICAL GRILLE BARS. (Note: number of clips may vary from
shown due to grille size and door style.
Sealant
Use the installation tool as shown
to push the clip completely into the
locked position.
Section Cut for Clarity
With all the clips installed, insert grille against clips on one
side. Gently push opposite side of grille against glass,
locking all clips into frame. Remember to gently press the
top and bottom of the grille against the glass.
Clips will be hidden when grille is inserted.
To remove, gently pull away from the glass surface at one
long side of the grille where the muntins meet the grille
frame.
3.48
2014 (U1 REVISED)
Shop 3
Grille Installation
Installation for Flush-Glazed
Classic-Craft®
Locate grille clips under molding
edges where molding meets glass.
Door
Preparation
11-7/16”
22-27/32”
21-17/32”
43-3/32”
Notch Locations
Insert grille clips
by sliding in spade
edge of clip under
molding and press clip
all the way in.
Bend slightly to
tighten fit with
grille if necessary.
Insert grille into door, placing one long
side against hardware.
Snap into place along all other sides.
Shop 3
2014 (U1 REVISED)
3.49
Lite Divider Installation
(Classic-Craft)
Door
Preparation
NOTE: TEMPERATURE RANGE FOR OPTIMUM TAPE ADHESION IS
70 TO 100 F. MINIMUM SUGGESTED APPLICATION TEMPERATURE
IS 60 F. THE DOOR AND LITE DIVIDER ARE TO BE IN THIS
TEMPERATURE RANGE. ALLOW 72 HOURS FOLLOWING
APPLICATION FOR FULL BOND STRENGTH ON TAPE.
1. Moisten a clean cloth with 70% Isopropyl Alcohol.
Wipe both sides of glass as shown at right.
NOT PREPARING THE GLASS WILL RESULT
IN POOR TAPE ADHESION.
2. Lay out dividers in desired pattern
in the lite opening. For the 4- and
6-lite packs: the long dividers are
placed vertically, the short dividers
are placed horizontally.
3. Position template in lower left
corner of lite opening (see page 2),
with the top of the template (as
marked) toward the top of the door.
4. Working with vertical dividers first,
remove carrier backing from the
divider. NOTE: ADHESIVE IS NOT
REPOSITIONABLE.
5. Position divider, adhesive side
toward the glass, using the
template as a guide for placement.
6. Press firmly to the glass to secure
adhesive. Note: allow 72 hours
following application for full bond
strength of adhesive.
7. Apply remaining dividers
(repositioning the template where
applicable) in the same manner.
Template
Position
EXAMPLE
Carrier backing
8. Repeat the same installation steps
for the other side of the door.
Recommendations:
Apply all vertical dividers BEFORE applying horizontal dividers.
Use a veneer roller over fully-position lite dividers to increase adhesion.
3.50
2014 (U1 REVISED)
Shop 3
Lite Divider Installation
(Classic-Craft)
Template Part Number:
TPA2618LD3-P
Template Part Number:
TPA2618LD2-P
2-Lite
Template
Position
Template Part Number:
TPA0866LDSL5-P
5-Lite
6’8” Sidelite
Template Position
Shop 3
4-Lite
Template
Position
3-Lite
Template
Position
Template Part Number:
TPA0818LDSL2-P
2-Lite
6’8” Craftsman Sidelite
Template Position
2014 (U1 REVISED)
Door
Preparation
6-Lite
Template
Position
Template Part Number:
TPA0880LDSL6-P
6-Lite
8’0” Sidelite
Template Position
3.51
SDL Bar Installation Instructions
(Smooth Star / Fiber Classic)
Door
Preparation
NOTE: TEMPERATURE RANGE FOR OPTIMUM TAPE ADHESION IS 70° TO
100°F. MINIMUM APPLICATION TEMPERATURE IS 60°F. BOTH THE DOOR AND
LITE DIVIDER ARE TO BE IN THIS TEMPERATURE RANGE. ADHESIVE IS NOT
REPOSITIONABLE.
Materials Needed:
70% Isopropyl Alcohol or adhesion promoting solution
Clean rags
½” Masking tape
J-Roller
Shim stock or business card
Pencil
Plastic zip ties or coffee stirrers
Sanding materials
When installing over GBG’s only use bronze flat bar patterns
Use notches to
mark frame
SDL Preparation for Interlocking Bar Patterns:
1.
Starting at the external glass side, take a horizontal divider and place
it at the top of the glass. Center the bar in the opening and use the
notch(es) on the divider to mark on the frame the top position of the
vertical divider(s). Slide the bar to the bottom of the glass and repeat
for the bottom position of the vertical dividers.
2.
Take a vertical divider and center between the frame markings. Mark
amount of bar to trim (if necessary). There should be 0.015” - 0.020”
clearance (use a business card as a shim) on each side to allow for
expansion or contraction. Repeat for each vertical divider. Be sure to
mark each divider with its location (left/right).
3.
Trim bars at appropriate angle (see below) to their correct size. Trimming may be done with a stationary belt
sander, disc sander, or sanding block.
Framed Lites
(7x64, 21x15, 22x47, 22x64)
Framed Lites
(8x36, 8x47, 20x64, 22x36)
45°
35°
Flush Glazed
(all sizes)
67°
4.
Place a trimmed vertical bar to one side of the glass and use the notches on the dividers to mark on the frame the
position of the horizontal dividers. Repeat on the other side of the glass.
5.
Assemble the vertical and horizontal bars together and center the bars on the glass at the frame markings without
removing the carrier backing tape. Mark amount of bar to trim (if necessary). There should be 0.015” - 0.020”
clearance on each side. Repeat for each horizonal divider. Be sure to mark each divider with its location
(top, bottom, center, etc).
6.
Disassemble bars. Trim bars at appropriate angle to their correct size.
3.52
2014 (U1 REVISED)
Shop 3
SDL Bar Installation Instructions
(Smooth Star / Fiber Classic)
7.
Assemble the horizontal and vertical divider(s). Use masking tape to secure the divider bars together at the joints.
Peel off the Carrier Backing from all of the divider pieces. Clean any trimming residue from tape using
70% Isopropyl Alcohol. Lightly place the tips of small zip ties or coffee stirrers roughtly 1/8” onto the adhesive
backs as shown. For each of the divider bars, position 1 tie at each end of the divider and each joint, and 1-2 ties
in the middle. The ties will keep the adhesive backing off of the glass during final positioning.
Carrier backing
Small Zip Tie
or Coffee Stirrer
Glass Preparation:
Moisten a clean cloth with 70% Isopropyl Alcohol or use an adhesion promoting solution. Wipe the glass before
attaching dividers. Allow to dry.
FAILURE TO PREPARE THE GLASS PROPERLY WILL RESULT IN POOR TAPE ADHESION.
DO NOT USE A GLASS CLEANER TO PERPARE THE GLASS AS THIS WILL PREVENT PROPER ADHESION.
SDL Installation:
1.
Position the divider grid back onto the glass using the frame position marks. Check to ensure that, for all of the
frame to divider points, there is a 0.015” - 0.020” gap between the divider and the frame. Once in position, press
down at all of the ends opposite the zip tie to lock the position, and then pull out that zip tie. Once all of the divider
ends are attached, pull out the middle zip ties from the dividers. Using a J-Roller, roll firmly along the entire length
of the horizontal and vertical dividers. Look through the interior side to confirm all dividers adhere to the glass,
particularly around the perimeter and divider joints. Once attached, remove the masking tape.
2.
Repeat steps for interior frame side.
Shop 3
2014 (U1 REVISED)
3.53
Door
Preparation
SDL Bar Installation Instructions
(Smooth Star / Fiber Classic)
SDL Preparation for Non-Interlocking Bar Patterns:
Door
Preparation
1.
Make template to the dimensions required for your lite pattern (see subsequent pages).
2.
Beginning with the exterior, position each divider using the proper template and mark position on the frame. Center
bar in opening. Mark amount of bar to be trimmed (if necessary). There should be 0.015” - 0.020” clearance
(use a business card as a shim) on each side to allow for expansion or contraction. Repeat for each divider. Be sure to
mark each divider with its location (top, middle, bottom, etc).
3.
Trim bars at appropriate angle (see below) to their correct size. Trimming may be done with a stationary belt sander,
disc sander, or sanding block.
Framed Lites
(7x64, 21x15, 22x47, 22x64)
Framed Lites
(8x36, 8x47, 20x64, 22x36)
45°
Flush Glazed
(all sizes)
35°
67°
Glass Preparation:
Moisten a clean cloth with 70% Isopropyl Alcohol or use an adhesion promoting solution. Wipe the glass before
attaching dividers. Allow to dry.
FAILURE TO PREPARE THE GLASS PROPERLY WILL RESULT IN POOR TAPE ADHESION.
DO NOT USE A GLASS CLEANER TO PERPARE THE GLASS AS THIS WILL PREVENT PROPER ADHESION.
SDL Installation:
1.
Peel off the Carrier Backing from all of the divider pieces. Clean any trimming residue from tape using
70% Isopropyl Alcohol. Lightly place the tips of small zip ties or coffee stirrers roughly 1/8” onto the adhesive
backs as shown. For each of the divider bars, position 1 tie at each end of the divider and 1-2 ties in the middle.
The ties will keep the adhesive backing off of the glass during final positioning.
Carrier backing
Small Zip Tie
or Coffee Stirrer
Zip Ties
2.
Position the dividers back onto the glass using the frame marks. Check that the dividers cover the internal
GBGs (if present). Press down on each end of the divider to lock the position and remove the zip tie. Repeat
for the other end. Remove the remaining zip tie(s). Using a J-Roller, roll firmly along the entire length of the
dividers. Look through the interior side to confirm all dividers adhere to the glass, particularly around the
perimeter.
3.
Repeat steps for the interior dividers. Check the alignment of the interior dividers with the exterior dividers
before attaching interior dividers.
3.54
2014 (U1 REVISED)
Shop 3
SDL Bar Installation Instructions
(Smooth Star / Fiber Classic)
21 X 15
2 LITE CRAFTSMAN
TOP
21 X 15
3 LITE CRAFTSMAN
TOP
6.500
9.480
6.500
5.940
TOP
TOP
Shop 3
Door
Preparation
2014 (U1 REVISED)
TOP
3.55
SDL Bar Installation Instructions
(Smooth Star / Fiber Classic)
7 x 64
5 - Lite
7 x 64
1 - Lite Craftsman
Flush Glaze
Flush Glaze
Lite Frame
Door
Preparation
8 x 64
5 - Lite
5 7/8
5 7/8
END
END
7
END
END
11 11/16
11 3/4
13 15/16
MID
5 7/8
END
END
MID
7
MID
MID
11 3/4
11 11/16
Lite Frame
5 7/8
END
END
Same Template
for END and MID
MID
11 11/16
MID
END
8 x 47
4 - Lite
Lite Frame
6 7/8
8 x 36
3 - Lite
Flush Glaze
END
END
7.000
END
END
10 11/16
10 15/16
6 7/8
MID
MID
Lite Frame
10 5/8
6 3/4
END
10 7/8
END
END
3.56
2014 (U1 REVISED)
Shop 3
Dentil Shelf Attachment
(Classic-Craft)
Shop
Installation
Instructions
for
Dentil Shelf
Attachment
The following instructions should be
completed in the door shop or at the job site.
Check to see that the shelf shop
pack is included with this unit.
The pack contains all the necessary
hardware and fasteners needed
to complete this installation.
Read all instructions before starting.
1
Door
Preparation
APPLY LOCATING TEMPLATE TO DOOR
Apply shelf locating template to door slab.
Align all three sides of the template to ensure
it is squared up with the door.
Hold template down with clamps if needed.
Template Part Number:
TPA30200-P (American Style)
Template Part Number:
TPCCVDS-P (Canvas)
2
DRILL PILOT HOLES
After getting shelf aligned with the template,
drill pilot holes with 1/8” drill bit at all three
attachment locations into wood block on
inside of the door.
Holes to be approximately ¼” to ½” in depth.
CAUTION:
DO NOT DRILL THROUGH ENTIRE DOOR.
Part Number: MACCASHELFINST REV. C
Shop 3
2014 (U1 REVISED)
3.57
Dentil Shelf Attachment
(Classic-Craft)
Door
Preparation
3
Shelf Installation Components
FASTEN SHELF TO DOOR
Fasten three screws into door at screw boss
locations until shelf becomes tight with door.
DO NOT OVER TIGHTEN.
OR
Dentil Shelf
CCADS04 OR CCADS16
Dentil Shelf
CCVDS04
4
INSERT PLUGS
Align grain and insert plugs into holes.
Press until plug is flush with shelf surface.
DISCLAIMER: SHELF IS NOT
INTENDED TO HOLD ANY OBJECTS
OR WEIGHT.
3.58
Shelf Screw
(3) #10 x 1-1/2”
Phillips Pan Head
Shelf Plug
(3) Plugs
CCAPLUG
P.O. Box 8780
Maumee, Ohio 43537
419-891-7400
Therma-Tru is a registered trademark of Therma-Tru Corp.
© 2011 Therma-Tru Corp.
2014 (U1 REVISED)
Shop 3
Dentil Shelf Attachment
(Smooth Star / Fiber Classic)
IMPORTANT:
Please read and understand all installation and adhesive instructions prior to opening the adhesive cartridge.
CAUTION: Make sure your work area is well ventilated. Keep adhesive away from heat and flame. Avoid any
contact with the eyes and skin. Read warning label on adhesive box. KEEP OUT OF REACH OF
CHILDREN.
NOTES: - When PAINTING, the door and dentil shelf should be unfinished when applying dentil shelf.
- When STAINING, the door and dentil shelf should be finished before applying the dentil shelf
- To be removed from the opening and placed in a horizontal position for a minimum of twenty-four hours
to allow the adhesive to cure.
- Recommended application temperature minimum 40°F.
TOOLS NEEDED: Safety Glasses, Latex Gloves, Mineral Spirits, Isopropyl Alcohol
INSTALLATION:
STEP 1: PREPARE THE DOOR
Protect the underside of the door by laying it flat on padded sawhorses or another padded surface. Position the door
with the exterior side facing up. Thoroughly clean the door surface and the dentil shelf with isopropyl alcohol. Surface
must be completely dry before going on to Step 2.
STEP 2: LOCATE SHELF
Position the dentil shelf on the door so that it is centered along the width of the door and parallel to the glass opening
(suggested location is 3/8” from the bottom of the glass). With a graphite pencil, lightly mark the locations of the top
and sides of the shelf on the door face.
STEP 3: APPLY ADHESIVE
Open adhesive cartridge apply a single 1/4” diameter bead of adhesive to the center of the wood core on the
underside of the shelf. Be careful not to allow adhesive beyond the wood to help prevent squeeze-out. Carefully press
the shelf onto the door face using your pencil lines (from Step 2) as your locating guides. Apply firm pressure to ensure
contact with door. You will have approximately 30 minutes to work with the shelf before the adhesive starts to set.
Immediately remove any adhesive squeeze-out with mineral spirits and a clean cloth.
STEP 4: CURE TIME
The shelf and door should remain in the horizontal position for a minimum of twenty four (24) hours to allow the
adhesive to cure. After this time, the door can be finished and installed.
STEP 5: ADHESIVE DISPOSAL
Wipe tip clean, and recap the product. Refer to MSDS on manufacturer’s website.
DISCLAIMERS:
-- SHELF IS NOT INTENDED TO HOLD ANY OBJECTS OR WEIGHT.
-- THE SHELF IS NOT RECOMMENDED FOR USE BEHIND A STORM DOOR.
Shop 3
2014 (U1 REVISED)
3.59
Door
Preparation
5DLQ'HÀHFWRU,QVWDOODWLRQ
Attach Rain Deflector
Door
Preparation
Sealant type must be a paintable or stainable elastomeric or polyurethane.
Exterior
Rain
Deflector
Base
Center rain deflector base on exterior face of panel
and align edge of rain deflector base with bottom
edge of panel.
Apply bead of sealant in channel on rain deflector base.
Channel
Sealant
Align
Attach rain deflector base to panel with #8 x 1”
phillips pan head screws.
Exterior
#8 x 1” stainless steel
phillips pan head screw
Base
Fin
Slide rain deflector fin into channel on base.
Apply a 2” long bead of sealant up under the fin
at the center of the door to prevent fin from sliding.
Sealant
Rain Deflector Cut Down Instructions:
Sealant
3.60
3/0 - No cut down required.
2/10 - Cut 1” off both ends of 3/0 deflector.
2/8 - Cut 2” off both ends of 3/0 deflector.
2/6 - Cut 3” off both ends of 3/0 deflector.
2/4 - Cut 8” off one ends of 3/0 deflector.
2014 (U1 REVISED)
Shop 3
Decorative Hinge
Strap & Clavos Application
Door
Preparation
3/8"
from
door
edge
INSTALLATION:
1. Locate strap hinges 3/8" from edge of
door at desired locations.
2. Using masking tape, mark the location
of the strap hinges on the door.
3. Moisten a clean cloth with 70% Isopropyl
Alcohol and clean the area where the
hinges will be applied.
4. Remove backing tape from the tape on
one hinge and attach it to the door.
NOTE: Hinge cannot be moved once
placed on the door.
5. Press the hinge firmly in place at the
location of each tape backer. 35 pounds
of force is required at each location.
6. Repeat for each other hinge.
INSTALLATION:
1. Locate clavos on door
at desired locations.
2. Using masking tape, mark the location
of the clavos on the door.
3. Moisten a clean cloth with 70% Isopropyl
Alcohol and clean the area where the
clavos will be applied.
4. Remove backing tape from the tape on
one clavos and attach it to the door.
NOTE: clavos cannot be moved once
placed on the door.
5. Press the clavos firmly in place at the
location of the tape backer. 35 pounds
of force is required.
6. Repeat for each clavos.
Shop 3
2014 (U1 REVISED)
3.61
3.62
2014 (U1 REVISED)
1 1/4" Square
3/6 Doors
Double Clavos
1 1/4" Round
1 1/2" Square
3/6 Doors
Single Clavos
1 3/4" Round
3/0 Doors
Double Clavos
1" Square
1" Round
1 1/4" Square
3/0 Doors
Single Clavos
1 1/4" Round
Clavos Examples
Decorative Hinge
Strap & Clavos Application
Door
Preparation
Shop 3
Decorative Hinge
Strap & Clavos Application
Shop 3
3/6 Doors
3/0 Doors
Strap Hinge Examples
Other Door Styles with Hardware Examples
Door
Preparation
2014 (U1 REVISED)
3.63
Special Shop Painting
Therma-Tru products are manufactured for use with high quality, exterior grade house paints.
Door
Preparation
following guidelines.
CAUTION:
Therma-Tru bears no responsibility for the performance of distributor-furnished
Therma-Tru makes no claims about the compatibility of its primers when coated
with special shop applied paints or topcoats.
Finishing With Materials Other Than High Quality, Exterior Grade House Paints
Automotive and industrial paints often contain stronger solvents than house paints. Because
Therma-Tru’s factory applied primer is intended for use with house paints, these stronger solvents
may attack the factory applied primer. For best performance, we recommend:
STEEL
x Use a water-based acrylic paint, instead of an epoxy or urethane.
x
The primer must, of course, be compatible with the topcoat being used.
CLASSIC-CRAFT, FIBER-CLASSIC and SMOOTH-STAR DOORS
x Use a water-based acrylic or alkyd-based (oil) paint, instead of an epoxy or urethane.
x
the topcoat. Use primers and topcoats that are compatible.
x Maximum temperature for quick dry should be 200°F or less.
3.64
2014 (U1 REVISED)
Shop 3
Special Shop Machining
Peep Sights
Two examples of Peep sights are shown below.
Peep sights vary by door style.
Please contact technical service for specific door information.
Door
Preparation
1/2” Dia.
1/2” Dia.
58”
58”
Centerline
of CC200
Door
Centerline
of CC060
Door
Mail Slots
Two examples of Mail slot machining are shown below.
Mail slot locations vary by door style.
Please contact technical service for specific door information.
11-1/2”
Centerline
of Middle Rail
2-11/16”
11-1/2”
Centerline
of Middle Rail
Typical Mail
Slot Opening
2-11/16”
Typical Mail
Slot Opening
Centerline
of CC060
Door
Shop 3
2014 (U1 REVISED)
Centerline
of CC200
Door
3.65
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