INSTALLATION INSTRUCTIONS for Exterior Door Slabs (JII107) Thank you for selecting JELD-WEN products. Attached are JELD-WEN’s recommended installation instructions for exterior steel, fiberglass, and wood door slabs. Read these instructions thoroughly before beginning. They are designed to work in most existing applications however; existing conditions may require changes to these instructions. If changes are needed, they are made at the installer’s risk. For installations other than indicated in these instructions, contact a building professional. Not all exterior door types may be installed into every wall condition in all areas. See our Appropriate Protection document for overhang requirements at www.jeld-wen.com. Consult your local building code official for applicable building codes and regulations. Local building code requirements supersede recommended installation instructions. Note to Installer: Provide a copy of these instructions to the building owner. By installing this product, you acknowledge the terms and conditions of the limited warranty as part of the terms of the sale. GLOSSARY Head Jamb The horizontal jamb across the top of the opening. Hinge Metal component that attaches the slab to the jamb and allows the slab to swing open and closed. Hinge Jamb The side jamb the hinges are mounted in. Hinge Leaves The flat parts of the hinge that mount to the jamb and slab. Hinge Pin Pin that holds the hinge leaves together and allows them to pivot. Hinge Route Mortise in the jamb and slab the same profile as the corresponding hinge leaf. Jambs Framework attached to the structure that the slab is mounted to, or hung in. Panel Component of the slab filling the spaces between the stiles and rails. Pilot Hole Adrilledholethatisnolargerthanthebodyofthescrew(minusthe threads). Rail Horizontal members of the door slab. Slab The operating part of the door assembly that swings open and closed inside a frame. Stile Vertical members of the door slab. Stop Componentfixedtotheinsidethejambthattheslabclosesagainst. Strike Jamb The side jamb that contains the latch strike to hold the slab closed. Please allow sufficient time to properly prepare the opening, install the slab, and ensure its proper operation. Estimated Install Time for New Construction First Time: 1½ hr Experienced: ¾ hr Professional: ½ hr 11 12 1 10 9 8 2 3 4 7 6 5 SAfeTyAnDhAnDLing SAFETY MATERIALS AND SLAB HANDLING •ReadandfullyunderstandALLmanufacturers’instructions before beginning. •Allowdoorstoacclimateforatleast24hourstolocalconditions before installation or finishing. •Donotworkalone.Twoormorepeoplearerecommended.Usesafe lifting techniques. •Usecautionwhenhandlingglass.Brokenorcrackedglasscancause serious injury. •Storeslabsinadry,well-ventilatedprotectedareaoffofthefloor. Buildingswherehumidityandtemperaturearecontrolledprovidethe beststoragefacilities(recommendedconditions30%-50%Relative humidityand50°fto90°f) •Wearprotectivegear(e.g.safetyglasses,gloves,earprotection,etc.). •Protectfromexposuretodirectsunlightduringstorage. •Operatehand/powertoolssafelyandfollowmanufacturer’s operating instructions. •handledoorswithcleanhandsorwhilewearingcleangloves. IF INJURY OCCURS, IMMEDIATELY SEEK MEDICAL ATTENTION! •Liftandcarrydoorstomove,donotdragacrossoneanother. •heedmaterialmanufacturers’handlingandapplicationinstructions. •installonlyintoverticalwallsandwhenconditionsaredry. INSTALLATION INSTRUCTIONS for Exterior Door Slabs (JII107) neeDeDMATeRiALSAnDTOOLS NEEDED MATERIALS NEEDED TOOLS •hinges •Safetyglasses •Woodscrews(minimum5/8"throughhinges; 1-21/2"throughinteriorholeinthetoptwohingesintoframing) •Screwdrivers •Circularsaw(fortrimmingwood doorsonly) •Pencil •Level •Chiselorrouter •Woodplane(fortrimmingor bevelingwooddoorsonly) •Woodputty/spackle •Locksetandtemplate •Drillwithbitsandholesaws •finishingsupplies •Tapemeasure •Maskingtape(fortrimmingwooddoorsonly) •150-280gritsandpaper Note! Follow all material manufacturers’ instructions for proper use and compatibility. 1 •inspectslabforcosmeticdamage,squarenessandwarp •Verifyitisthecorrectproduct(size,color,design,handingetc.) ifanyoftheaboveconditionsrepresentaconcern,donotinstallthe slab. Contact the supplier for recommendations. inSPeCTexiSTingjAMB •existingjambshould be3/16"wider than the slab and atleast5/8"taller. There should be enough distance between the jamb edge and the stop to accommodate the thickness of the slab. •Verifytheexistingjambislevelandplumb(C)and(D).Themaximum allowabledeviationis1/8". Verify Square, Level, & Plumb •Verifytheexisting jamb is square. The(A)and(B) measurements should be the same. Maximumallowable deviation from squareis1/4". 3 •Punch ReMOVePACKAgingAnDinSPeCTSLAB •Removeshippingmaterialssuchascornercovers,shippingblocks or pads. 2 •finishingtools(paintbrushes, roller, spray equipment, masking tapeetc.) •hammer •Theopeningfloororsillmustbeflatandlevel(notbecrownedor sagged)(D). e A C B •Thefaceoftheroughopeningmustbeinasingleplane(e)withless than1/8"twistfromcornertocorner. Donotinstalltheslabunlessthejambmeetstheaboveconditions. Professional assistance may be necessary to correct any problems before installation. D inSTALLSLAB IMPORTANT: The door slab should be finished (painted or stained) on all six sides with an equal number of coats after all routing, trimming, boring and touch-up has been completed and it has been properly fit in the jamb. Failure to finish on all six sides and install into a square, level and plumb condition could result in denial of warranty claims for operational or performance problems. See our finishing document at www.jeld-wen.com for finishing requirements and details. frame/stop PREPARE JAMBS AND SLAB 1.Measuretheexistingframe(notthestop)fromthetopofthe threshold to the bottom of the head and from side to side in several placestoverifytheslabwillfit.Theframeshouldbe3/16"wider thantheslab(1/16"clearanceonthehingejamband1/8"clearance onthestrikejamb)andtallenough(usually5/8"taller)toallow1/8" clearanceontheheadjamband1/2"betweenthebottomoftheslab and the top of the threshold. 2 Weatherstrip INSTALLATION INSTRUCTIONS forexteriorDoorSlabs(jii107) 3 inSTALLSLAB-COnTinUeD TRIMMING ALLOWANCE- FOR WOOD DOORS ONLY 1.ifnecessaryto fittheexisting jamb,amaximum of1/4"canbe trimmed from each side. For the best appearance, trim an equal amount from opposite sides. To minimize chipping, stick masking tape along the cut line to each face of the slab. Make the cuts with a fine toothed circularsaw(height) and wood plane (width).Trimming beveled edges may requirere-beveling. 2.Thelatchstilemay haveapre-cut2˚or 3˚bevel.Thisbevel maintainsa1/8" clearance between the jamb and latch edge and improve the fit when the slabisclosed.if the latch stile is not beveled, and a bevel is preferred, use a wood plane orfine-toothedsaw to cut a bevel so that the slab face that rests against the stop becomes slightly narrower than the opposite face. INSTALL HINGES 1/4" Top rail Trim-able portion 1/4" Stile Bottom rail Trim-able portion 1/4" Stop Bevel Slab TEST SLAB FIT IN JAMBS Beforeinstallingany hardware, fit the slab in the frame and verify it will fit properly. Looking at the hinge side of the slab when it is closed, thereshouldbe1/16" gap between the slab and hinge jamb and1/8"betweenthe slab and the head and strike jamb. 3 1/8" 1/8" 1/16" 1.Threehingesarerecommendedforslabsupto84"inheightandfour hingesforslabsover84". 2.ifre-usingexisting jambs, verify the existinghinge locations are plumb, or all in a straight line vertically. Position the new hingesintheexisting Plumb locations and modify line the mortises as necessary. Fill and re-drillscrewholes if necessary. Match the slab to the jambs using the following instructions. 3.ifinstallingnew jambs, measure down from the underside of the top 7" 67/8" ofthejamb(notthe stop)7"toposition the top of the top hinge. Measure up from the top of the threshold10"to position the bottom of the bottom hinge. Place the middle hinge halfway in between. 4.Whenmarkingtheslabforhinges,makesurethemeasurementfrom thetopoftheslabtothetopofthehingerouteis1/8"smallerthan the distance from the head jamb to the top of the top hinge. This will allow1/8"gapbetweentheslabandheadjamb. 5.Whenmarkingthe slab, the distance from the inside face Hinge Slab to the back of the jamb hinge route should be1/16"lessthanthe depth of the hinge 1/4" route on the jamb. 3/16" 6.Usingatemplate, mark the jambs and slab where the hinges will be mounted.Using Stop a chisel or router, notch the jamb and slab for the outline of the hinge leaves and no deeper than the thickness of the leaves. 7.Usingthehingeasatemplate,markscrewholelocationsanddrill pilotholesforallscrews.ifpossible,itmaybeeasiertoremovethe hingepintoseparatethehingeleaves.Useahammerandapunchto drivethepinfromtheopenend.installthehingeleavesseparately on the jambs and slab. Then, hang the slab in the frame by aligning the hinge leaves and reinstall the hinge pins. INSTALLATION INSTRUCTIONS forexteriorDoorSlabs(jii107) 4 COMPLeTeinSTALLATiOn INSTALL LOCKSET AND FINISH INSTALLATION 1.Mostlocksetholes willbepre-drilled and the lockset can Panel be installed per Lockset hole the manufacturer's instructions.ifthe lockset hole is not pre-drilled,follow Rail the instructions in step2,otherwise, 23/8" skiptostep3. Latch 2.if installing into hole existing jambs, bore for the lockset where it will align with the existing strike. ifinstallingnewjambs,thecenteroftheholeforthelocksetis usuallycenteredintherail(horizontalmember)acrossthecenterof theslabor35"fromthebottomoftheslab(notthesweep).Lockset holesshouldbeeither23/8"or23/4"oncenterfromtheedge, dependingonthelatch.Usingthelocksetmanufacturer'sinstructions andtemplate,drillforlockset.generally,a21/8"diameterholeis neededforthelockset.Drilla1"latchholethroughtheedgeofthe slab into the center of the lock hole to accommodate the latch for thelock.Somelatcheshavearadius(roundedcorners)orrectangular faceplatethatwillrequiretheslabedgetobechiseledforfit.Drill pilotholesforattachmentscrews.Otherlatchesareround(contractor drive-in)andcanbetappedintoplacewithahammer.installlockset per manufacturer's instructions. 3.Closeslabandcheckforproperoperation.Adjustasnecessary. 4.Removehardwareandfinishallsurfacesoftheslabifnotalready done. Please visit jeld-wen.com for finishing instructions, warranty and care and maintenance information. Thank you for choosing ©2012 JELD-WEN, inc.; This publication and its contents are owned by JELD-WEN, inc. and are protected under the U.S. Copyright Act and other intellectual property laws. All trademarks, service marks, logos and the like (whether registered or unregistered) are owned or controlled by JELD-WEN, inc. or others. Unauthorized use or duplication of JELD-WEN intellectual property is prohibited. JELD-WEN reserves the right to change product specifications without notice. Please check our website, jeld-wen.com, for current information. 4 (09/12)
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