JELD-WEN 794851, 794852, E22669, 794861, 5389.0, 794850, A01659, 794865, A01660, THDQC230000137 Installation guide

JELD-WEN 794851, 794852, E22669, 794861, 5389.0, 794850, A01659, 794865, A01660, THDQC230000137 Installation guide
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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