Builders Choice HDXD184165, HDX162798, HDX163979, HDXD189474, HDXD184523, HDX162507, HDX162835, HDXD184257, HDX163290, HDX163719 Operating instructions

Builders Choice HDXD184165, HDX162798, HDX163979, HDXD189474, HDXD184523, HDX162507, HDX162835, HDXD184257, HDX163290, HDX163719 Operating instructions
PRE-HUNG DOORS
Style | Quality | Selection
INSTALLATION GUIDE
PRE-HUNG DOOR INSTALLATION
Builder, Subcontractor or Supplier:
Please forward these instructions to the homeowner. The application performance standards for these products may be governed by
the International Residential Code, International Building Code and other state and jurisdictional requirements.
Installation Instructions for Pre-hung Door Systems
Required Tools & Materials:
These installation instructions are designed to assist door installers who have an
understanding of carpentry principles, and know how to properly and safely use
power tools. The purpose of these instructions is to illustrate how to install a Builders
Choice door system using methods and materials that help eliminate water related
leaks. If the directions are closely followed, the door system will have a long useful life
with good resistance to rain related water intrusion problems.
• 2 & 6 foot Levels
• Hammer
• Putty Knives (firm & flexible)
• Framing Square
• Caulking Gun
• Sturdy Ladder
• Shims
• Tape Measure
• High Quality Elastomeric or Polyurethane
Sealant
• Optional Sill Pan
• Screw Gun/Drill -1/8 inch Drill Bit
• Razor Knife
•#2 & #3 Philips Bit
• Stapler
• Insulating Material
• Eye Protection
• Water Resistive Barrier
• Flashing Material
•#8 x 2-1/2 inch Exterior Grade Screws
These methods are “tried and true.” They are used widely by builders and remodelers
who are serious about managing and keeping water outside the home. If you remain
unclear, please seek more professional assistance with the installation.
Different parts of the country have different code requirements, which may not be
covered in these instructions. The installer is responsible for insuring the installation
complies with local codes.
If disturbing existing paint, take proper precautions if lead paint is suspected (commonly
used before 1979). For information regarding lead paint regulations, refer to www.
epa.gov/lead. For products being removed, always ensure that these products are
properly disposed of or recycled in accordance with local jurisdictional requirements.
Read all instructions before starting.
Builders Choice Recommended Best Practices | Use Water Resistive Barrier and Flexible Flashing:
We recommend the use of a Water Resistive Barrier (WRB) applied to the exterior sheathing (OSB or other) and the use of an adhesive
or flexible flashing product to seal around the opening. The WRB should be cut in the opening (follow manufacturer’s guidelines) with
the head of the flap taped up, to be sealed later in Step 11. The flashing should be applied in an overlapping manner as shown, always
working from the bottom up (follow manufacturer’s guidelines). Use a Sill Pan: We recommend you first “dry fit” the sill pan in the opening,
following the instructions furnished with the sill pan. Place the right and left sill pan ends tight against the sides of the opening. Check
the center section for proper length and if necessary, cut with a hack saw or tin snips. Be sure to allow 2 inches of overlap at the joints.
Note: Use only the PVC cement provided in the sill pan kit to glue the pieces together. The sill pan must be sealed to the sub-floor using
an Elastomeric or Polyurethane sealant, but do not apply sealant to the bottom of the sill when using a sill pan.
2
STEP 1: Check Door Unit
Check width and height.
Measure size of frame (width and height), not brickmould.
Remove cleats and packaging, but keep door fastened closed
with transport clip. DO NOT remove the transport clip until
instructed to do so later in Step 7.
STEP 2: Check & Prepare Opening
Is the opening the correct size for the door unit? Check it against
the door frame size now, before installation. The opening should
be frame height plus 1/2 inch, and frame width plus 1/2 inch to
3/4 inch. Fix any problems now.
Are the framing and walls PLUMB? Use a 6 foot level and check
both sides of the opening, both ways (front to back and right to
left). Fix any problems now.
Is the sub floor level and solid? Provide a flat, level, clean weight
bearing surface so the sill pan or sill can be properly caulked and
sealed to the opening. Scrape sand or fill as required.
Note: If additional floor covering clearance is required, attach
the shim board to the sub floor. Be sure to caulk well under the
shim board.
Is the opening square? Check all corners with a framing square.
Double check by comparing diagonal measurements. Fix any
problems now.
Check to be sure the framing walls around the opening are in
the same plane. Do this by performing a “string test” for plumb.
String Test for Plumb: Attach a string diagonally across the
opening from the outside, as shown. The string(s) should gently
touch in the center, if not the opening is “out of plumb” by twice
that distance and needs to be corrected. Flip the string over
itself to check both planes. Fix any problems now. *An “out of
plumb” condition is one of the most common reasons door units
leak air and water.
STEP 3: Caulk the Sub Floor
On the sub floor at opening, place 3 very large beads of sealant.
Run beads full width of the opening.
Use Only Elastomeric or Polyurethane sealant.
Use an Entire Tube when Caulking along the Sub Floor.
3
STEP 3A: Installation with a Sill Pan
Place the right and left sill pan ends onto the caulk beads and
tightly against the side of the opening.
Then, liberally coat the overlapped areas and the recessed
areas of the pieces with the PVC cement provided. Place center
section(s) in position and hold pieces together long enough to
ensure a good bond.
For added protection, spread a bead of caulk along the glue
joints and to prevent air infiltration, run a bead of caulk along
the lower interior edge of the sill pan. Additional caulking could
affect the performance of the sill pan.
Do Not Caulk the bottom of the Sill when using a sill Pan.
STEP 3B: Installation without a Sill Pan
Lay the door unit on edge or face so that the bottom surface of
the sill can be caulked. Place very large beads of caulk across the
full width of the sill. Additionally, place beads of caulk along the
junction of the sill and the jamb and on the bottom surface of the
jambs and brickmould.
Note: If a sill extender is used, place a large bead of caulk at the
junction of the extender and the sill approach.
Important!
Apply sealant to the back side of brickmould around the entire
perimeter of the door unit. A 1/2 – 5/8 inch bead of Elastomeric or
Polyurethane caulk is essential.
STEP 4: Place Unit in Opening & Temporarily Fasten
Lift the unit up. With top edge tilted away from opening, center
the unit and place sill down onto sill pan or caulk beads and tilt
into opening.
For all door unit configurations, note the hinge locations and mark
those locations on the jamb faces near the door surfaces. Pre-drill
1/8 inch diameter holes at these locations for screw placement. A
counter sink bit will help to conceal the screw heads.
Install screws in the center pre-drilled hole locations on both jambs
to temporarily secure the unit in the place. Do not drive screws
completely in at this time. Use #8 x 2-1/2 inch or 3 inch exterior
grade screws.
Do Not Fasten through the Brickmould.
4
STEP 4
(continued) :
Plumb Hinge Side Jamb
Work from side of the door that is weather-stripped.
Use a 6 foot level and plumb the hinge side jamb both ways
(right to left and inside to outside).
Place screws through the hinge side jamb into the studs, at
each remaining hinge location, as shown in the diagrams. Use
#8 X 2-1/2 inch or 3 inch exterior grade screws.
DO NOT drive the screws completely in at this time.
For Single or Double Doors, place screws at each hinge
location, so shims can be placed behind hinges above
screws. The screws will keep the shims from falling down while
adjustments are being made.
For Sidelite units, fasten the jamb on the hinge side of the door.
Single Unit
For Double Door and Patio Units, fasten the fixed or passive side
of the unit first.
STEP 5: Shim at Hinge Locations & Secure Hinge Jamb
Leave door fastened and closed with transport clip.
Shim above screws, behind each hinge location, between the
opening and the jamb.
Use a 6 foot level and re-check hinge jamb to ensure it is plumb
and straight.
Finish driving screws tight in the middle first then top and
bottom last.
STEP 6: Adjust Rest of Frame & Fasten
From the weatherstrip side of the door, check weatherstrip
margins and contact.
Make frame adjustments so the weatherstrip contacts the door
surface equally at the top, middle and bottom, an even 3/8
inch to 1/2 inch when fully closed.
Secure the lock side jamb with #8 X 2-1/2 or 3 inch screws
through the pre-drilled holes at the top and bottom. Do Not
drive screws tight at this time.
From the swing side of the door, shim above the screw locations
and make adjustments so the margins between the door and
frame are even top to bottom.
Note: For Double Doors, make adjustments that effect the
alignment, margins and weatherstrip contact between the
doors. Also follow the Astragal Site Package Instructions
for details on properly setting the slide bolt hole locations.
Re-check everywhere for plumb and square, and an even
weatherstrip contact. Finish driving all screws tight.
5
Sidelite Unit
Double Unit
STEP 7: Remove Door Plug & Open Door
Remove the door plug. Open and close door to check for
smooth operation.
With the door open at the top hinge, drill 1/8 inch diameter pilot
holes in the screw hole locations closest to the weatherstrip (if
no screws previously installed). If screws are previously installed,
remove 3/4 inch screws and install #10 x 2-1/2 inch screws. For
middle and bottom hinges, proceed to install one (1) #10 x 2-1/2"
screw in the bottom hole, closest to the weatherstrip. Make sure
all installed screws go through the hinge, into the stud, to anchor
the door frame and prevent sagging.
For Sidelite and Patio Units that are hinged at the center:
With the door open, check to determine if the 2-1/2 inch long
hinge screws were pre-installed in the hinges. If not, drill 1/8 inch
diameter pilot holes and install the long hinge screws in the hole
locations closest to the weatherstrip.
Close the door and carefully shim between the jamb and the
opening behind the strike plate area.
Then open the door and drill 1/8 inch dia. pilot holes and install
the #8 X 2-1/2 inch screws (provided) through the strike plate
holes to secure the lock side jamb and provide security.
STEP 8: Adjust Sill
Your door unit may have an adjustable threshold cap. When
properly adjusted, it should be snug and slightly difficult to pull
a dollar bill out from under the door when it is fully closed. The
dollar bill should be able to be removed without tearing.
This check should be performed at each adjustment screw
location.
After adjusting the threshold cap, ensure that the weatherstrip
is flush with the top of the threshold cap. Trim as necessary.
STEP 9: Install Corner Seal Pads
(Inswing Units Only)
Apply sealant (Polyurethane or Elastomeric) at the joint where
the threshold cap meets the door jambs.
Remove the self-stick paper from the corner seal pads and apply
to the door jamb, with the bottom lined up evenly with the top of
the threshold cap. When the pad is correctly installed, the tab is
on top and the narrow part is on the bottom.
The bottom of the pad is the same width of the threshold cap to
help with alignment during installation.
6
STEP 10: Additional Frame Anchoring
If sill is prepared for anchoring screws, place appropriate screws
through the sill into the sub floor where needed (primarily on
outswing sills).
We recommend that you provide additional frame anchoring as
shown here. Certain states or jurisdictions, notably Florida and
the coast of Texas, have specific installation requirements and
may require installation in strict accordance with the product
approval for a specific product. You should always check with
the local authority having jurisdiction for any specific installation
requirements that may apply.
Door with Sidelites
Doors with Sidelites:
Shim above mull post or jambs separating doors and sidelites.
Screw through the frame into the header, adjacent to the shims.
Double Doors:
Place temporary shims above the center of the head frame,
where doors meet. Pre-drill and insert a screw through frame into
header, then remove the temporary shims.
Double Doors
Patio Doors:
Shim above the mull post(s), pre-drill and insert a screw through
the frame into the header, at either side of the post.
Patio Doors
STEP 11: Weatherproof, Finish & Maintain
All 6 sides of the doors must be finished. For out-swing doors the
sides, top and bottom must be inspected and maintained as
regularly as all other surfaces.
Provide and maintain a properly installed cap or head flashing
to protect top of surfaces from water intrusion and damage.
Tape and properly seal the top flap of the water resistive barrier
(WRB) over the head flashing.
All bare wood surfaces such as the door frame exposed to
weather should be primed and painted or stained and top
coated within two weeks of exposure for best performance.
Caulk around entire “weather” side of unit, sealing along the
brickmould to the flashing material or siding and seal all joints
between the jambs and moldings.
Maintain or replace sealants and finishes as soon as any
deterioration is evident. For semi-gloss or glossy paint or clear
coats, do this when the surface becomes dull or rough. More
severe climates and exposures will require more frequent
maintenance.
Seal the joints between the exterior hardware trim and the door
face to prevent air and water infiltration.
Place and set galvanized finish nails through the brickmould
around the perimeter. Use exterior grade screws if you are
installing a storm door to the brickmould. Countersink all fasteners
and cover with exterior grade putty.
Add insulation material to the cavity between the opening and
the unit to reduce air infiltration and heat transfer.
All Builders Choice doors must be finished within several days
of the installation date for continued warranty coverage. For
Fiberglass doors the finishing requirement is within 6 months of
installation.
Paint according to Builders Choice Finishing instructions. DO
NOT paint or stain the weatherstrip, it is “friction-fit” and easily
removed for painting or staining.
7
FINISHING INSTRUCTIONS
a TSP solution. Rinse well and allow to dry completely. Mask
off glass. Prime door lite frames with an alkyd- or acrylicbased primer. Allow primer to dry before applying finish paint
coats. Use high-quality acrylic latex house paint, following
manufacturer’s application instructions. Use exterior grade
finishes for outside surfaces.
Work only when temperatures are between 50° and 90°F and
with humidity less than 85%. Do not finish in direct sunlight.
Steel and Smooth Fiberglass Doors:
To paint Doors: Clean first with mild detergent and water or
use a TSP (tri-sodium phosphate) solution. Rinse well and allow
to dry completely. Mask off hardware, glass and remove
weatherstripping before painting. Use high-quality acrylic
latex house paint, following manufacturer’s directions for
application. Use exterior grade finishes for outside surfaces.
Paint edges and exposed ends of door.
To Paint Doors:
Clean first with mild detergent and water or use a TSP (trisodium phosphate) solution. Rinse well and allow to dry
completely. Prime with an alkyd- or acrylic-based primer.
Allow primer to dry completely, then paint with acrylic latex
house paint, following paint manufacturer’s application
instructions. Use a primer and paint that are compatible. Use
exterior grade finishes for outside surfaces. Paint edges and
exposed ends of door.
To Paint Door Lite Frames:
Remove any excess glass glazing sealant by first spraying with
a window cleaner or water. Use a single edge razor blade to
score the glazing along the edge of the frame. Holding the
razor blade at a 45 degree angle, scrape glazing from glass.
Wipe remaining residue off with window cleaner or mineral
spirits. Clean frame with a mild detergent and water, or use
WARNING: Modification or machining of this product can release wood
dust, a substance known to the State of California to cause cancer.
8
STEP 10: Additional Frame Anchoring
If sill is prepared for anchoring screws, place appropriate screws
through the sill into the sub floor where needed (primarily on
outswing sills).
We recommend that you provide additional frame anchoring as
shown here. Certain states or jurisdictions, notably Florida and
the coast of Texas, have specific installation requirements and
may require installation in strict accordance with the product
approval for a specific product. You should always check with
the local authority having jurisdiction for any specific installation
requirements that may apply.
Door with Sidelites
Doors with Sidelites:
Shim above mull post or jambs separating doors and sidelites.
Screw through the frame into the header, adjacent to the shims.
Double Doors:
Place temporary shims above the center of the head frame,
where doors meet. Pre-drill and insert a screw through frame into
header, then remove the temporary shims.
Patio Doors:
Shim above the mull post(s), pre-drill and insert a screw through
the frame into the header, at either side of the post.
Double Doors
Patio Doors
STEP 11: Weatherproof, Finish & Maintain
Provide and maintain a properly installed cap or head flashing
to protect top of surfaces from water intrusion and damage.
Tape and properly seal the top flap of the water resistive barrier
(WRB) over the head flashing.
Caulk around entire “weather” side of unit, sealing along the
brickmould to the flashing material or siding and seal all joints
between the jambs and moldings.
Seal the joints between the exterior hardware trim and the door
face to prevent air and water infiltration.
Place and set galvanized finish nails through the brickmould
around the perimeter. Use exterior grade screws if you are
installing a storm door to the brickmould. Countersink all fasteners
and cover with exterior grade putty.
Add insulation material to the cavity between the opening and
the unit to reduce air infiltration and heat transfer.
9
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