CLEANCUT STEP

INSTALLATION GUIDE

COPYRIGHT © 2015 SAFEWAY SAFETY STEP, LLC

(DBA “CleanCut”)

All Rights Reserved

Reproduction or Distribution of this Installation Manual is Strictly

Prohibited

IMPORTANT – PLEASE WATCH VIDEO PRIOR TO READING

DIRCTIONS AND BEGINNING INSTALLATION

THIS INSTALLATION MANUAL SHOULD BE USED IN CONJUCTION

WITH THE INSTRUCTIONAL DVD INCLUDED WITH THE CLEANCUT

STEP INSTALLATION KIT.

IT IS VERY IMPORTANT THAT ALL INSTRUCTIONS IN THE

INSTALLATION MANUAL AND INSTRUCTIONAL DVD ARE FOLLOWED

THOROUGHLY.

INSTALLATION OF THE CLEANCUT STEP REQUIRES USE OF

POTENTIALLY DANGEROUS TOOLS.

SAFEWAY SAFETY STEP, LLC (DBA “CLEANCUT”) ACCEPTS NO

RESPONSIBILITY FOR ANY TYPE OF INJURY, LOSS OR DAMAGE

OCCURRED DURING INSTALLATION OR SUBSEQUENT USE OF THE

CLEANCUT STEP.

FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS INSTALLATION

MANUAL AND THE INSTALLATION DVD SHALL VOID ANY

WARRANTY GIVEN WITH RESPECT TO THE CLEANCUT STEP.

IMPORTANT REMINDER - PLEASE RETURN THE PACKET THAT

INCLUDES WARRANTY REGISTRATION INFORMATION.

ADDITIONAL QUESTIONS?

CLEANCUT REPRESENTATIVES ARE AVAILABLE TO ANSWER

QUESTIONS MONDAY-FRIDAY FROM 9AM-4PM EST.

FOR QUESTIONS, PLEASE CALL (877) TUB-STEP (882-7837).

Thank you for your interest in the CleanCut Step. This installation manual includes an overview of the CleanCut Step installation kit as well as instructions pertaining to the step-by-step instructions for CleanCut Step installation.

CleanCut Step Installation Kit

The CleanCut Step installation kit includes the following items:

• One CleanCut Step (large/wide, medium or small/narrow)

• One CleanCut Step Support Box Structure (large & small box)

• Template to be used for cutting the tub

• Two tubes of recommended adhesive and angled extension

Tools & Materials

In addition to the items included in the installation kit, the following tools and materials are recommended to have on hand for installation.

Additional Tools & Materials

2 x 4’s

Card Paper

Caulking Gun

Chisels

Denatured Alcohol

Drain Screens

Drill & Drill Bits

Drop Cloths

Dust Masks

Dust Pan & Brush

Ear Protectors

Extension Cord

Protective Eye Wear

Gloves

Hammer

JigSaw with 2” Blade

Masking Tape

Mirror (small)

Paper Towels

Pliers

Deburring Tool

Drywall Plane (Rasp)

Reciprocating Saw with Metal Blades

Scissors

Screw Driver

Screws- Assorted Size

Side Grinder with 4.5” Diamond Blade*

Stanley Knife

Red Sharpie Marker

Vacuum

Vacuum Attachment for Grinder*

Wood Shims

*These items and other materials available for purchase from

CleanCut, LLC

Preparing the Tub

1. Before beginning any work, it is important to inspect the tub for existing chips, markings or other types of damage. It is always wise to make the owner or manager aware of any existing damage prior to beginning the installation process.

2. Prior to beginning the installation, remove any personal items from the bathroom area to create extra space during the installation and to prevent possible damage or exposure to dust and debris that may result during the installation process.

3. One method to minimize the areas where dust can settle is to use a 2-ply drop cloth with the paper side up to catch and trap dust and other shavings. In particular, a drop cloth should be taped into the bottom of the tub. This will help to collect debris as well as to help prevent accidentally scratching the bottom surface of the tub. The drain of the tub should be completely covered to prevent any shaving from going down into the drain. Make sure that there is no water or dampness in or around the tub.

Due to the significant amount of dust created when cutting a cast-iron tub, it is recommended that all walls and surfaces are covered, including the floor, before cutting the tub. See other considerations for cutting cast-iron tubs in the following section.

4. Once the tub area is prepared for installation, it is necessary to mark the tub to determine the section that will be cut to make room for the CleanCut Step. First, measure the length of the tub and determine the midpoint of the tub and measure back, half the distance of the CleanCut Step itself. Using the template that was included in the installation kit, place the template flush against the tub and begin tracing, Use a red sharpie marker so as to make the lines that are traced easily visible. Flip the template over and now trace the outside of the tub. Keep in mind that it may not be possible to place the CleanCut Step directly in the center of the tub due to obstructions in the tub area such as the placement of sinks, vanities or commodes and the use of shower seats may warrant moving the opening forward as well.

Cutting the Tub

The tub has been marked and is ready to cut. Safety is of highest importance and it is critical to remember to use the proper safety equipment when cutting the tub.

Protective eye and ear wear and filter mask are required.

The CleanCut Step can be installed in fiberglass, steel or cast-iron tubs. On fiberglass or steel tubs, use a side grinder with the diamond blade to make necessary entry points for the reciprocating saw. For cast-iron tubs, the side grinder with the diamond blade is the only cutting tool used. If you are cutting a cast-iron tub, please read the special considerations noted below before beginning to cut.

1. The first corner notches will be made with the side-grinder as illustrated in Figure

1 below.

2. Using the reciprocating saw on fiberglass and steel tubs, cut out the bottom markings on each side of the tub.

3. Then cut all four downward cuts. Finish by cutting the two adjoining top pieces.

FIGURE 1

4. The opening for the CleanCut Step is now completed and you can remove the cut-out section. Use caution when removing the cut-out section as there may be sharp or jagged edges both on the cut-out segment and along the edges of where the cuts were made on the sides of the tub. It is helpful to spend a moment to file down any potential hazard areas. This prevents potential snags with fitting the CleanCut

Step and reduces the risk of injury.

5. After the cut out section of the tub has been removed, take a few moments to clean the area in around the tub. Using a dust pan and broom, sweep all dust and shavings. Complete the clean-up by thoroughly vacuuming the entire area. Wash your hands before you start any work on the step itself. This will eliminate transferring any dirt or dust to the step.

SPECIAL CONSIDERATIONS FOR CUTTING CAST-IRON TUBS

Due to the significant amount of dust created when cutting a cast-iron tub, it is recommended that you cover all tub and exposed bathroom walls and surfaces

(including the floor) with a 2-ply drop cloth to minimize the amount of dust that can settle. Also, it is recommended that the installer wears protective cover-alls and shoe covers, in addition to protective wear outlined earlier, to minimize the clean-up after cutting out a cast-iron tub.

Please note that there are several differences when cutting out a cast-iron tub compared to a fiberglass or steel tub. The side-grinder with a 4.5” diamond blade is the only tool used when cutting a cast-iron tub. Cast-iron tubs are a bit more challenging to cut. Vacuum the dust and shavings as you cut the tub with the use of the Dust Buddie that contains a cover plate and vacuum attachment. The Dust

Buddie connects directly to the grinder to minimize dust output when cutting the cast-iron.

Follow the same pattern when cutting a cast-iron tub as described for the fiberglass and steel tubs. Begin by cutting the bottom lines of your template, followed by the downward vertical cuts leaving the top adjoining pieces for last.

Be cognizant of potential safety issues when cutting the tub such as sparks generated during cutting as well as items that may be located within the tub wall such as water lines, electrical lines, insulation or other items.

Measuring & Cutting the CleanCut Step

Once you have completed cutting out a section of the tub, you can begin to fit the

CleanCut Step into the tub opening. The first step is to determine which size

CleanCut Step you will need to complete the installation. The CleanCut Step is manufactured in three (3) sizes to fit tubs of varying widths. First, measure the top rail width measurement as well as the width measurement approximately 9.5” down the tub (bottom measurement). Based on these measurements, please consider the following:

• Small/Narrow CleanCut Step



The maximum top rail measurement to order a small/narrow CleanCut Step is

4.25”.



The maximum bottom measurement to order a small/narrow CleanCut Step is

5”.

• Medium CleanCut Step



The maximum top rail measurement to order a medium CleanCut Step is

4.75”.



The maximum bottom measurement to order a medium CleanCut Step is 6”.

• Large/Wide CleanCut Step



The maximum top rail measurement to order a large/wide CleanCut Step is

6.25”.



The maximum bottom measurement to order a large/wide CleanCut Step is

7.25”.

1. Take a stack of heavy card stock paper. This is the paper used to trace the cutout section of the tub onto the CleanCut Step. Place the card paper onto the left end and trace the outline of the pattern onto the paper. Once completed, mark this tracing as “Left”, so as to remember which side was traced. It is also helpful to place an arrow on the template to indicate which direction is the inside of the tub.

2. Repeat the process for the right side of the tub. Mark this tracing “Right”.

3. Cut out the proper templates with scissors making sure to keep to the inside of the tracings.

FIGURE 2

4. It is time to transfer the shape of our cut tub onto the CleanCut Step. Before continuing, it is recommended that a drop cloth approximately 3’ x 4’ size be placed on the floor to prevent any dust or other debris from transferring onto the CleanCut Step.

5. Place the right end of the CleanCut Step on the ground in order to trace the left side of the CleanCut Step. Place the top of the paper template approximately

½” from the top of the CleanCut Step (Figure 3). Place the tracing on the step so the slope is similar to that of the tub. Trace the outline of the paper onto the

CleanCut Step with a continuous line. Continue the lines with a straight edge down and around the corners. Repeat the same procedure for the right end of the CleanCut Step. Remember to place the paper template approximately ½” down from the top of the CleanCut Step before beginning to trace. Continue the lines with a straight edge down and around the corners.

PATTERN MARKS - - - - - - - INDICATE THE AREA TO BE CUT

OUT ON THE LEFT END OF THE STEP.

FIGURE 3

SIDE VIEW OF LEFT END OF STEP

6. Place step as shown and connect each side of the outside tub line using a yard stick (Figure 4).

FIGURE 4

7. Use a tape measure and transfer the shape of the inside of the tub edge to the step. The inside of the tub may be irregular in shape, so measurements for the inside line must be made every 3” from one end of the CleanCut Step to the other. Once completed, use your yard stick and marker to connect the markings for the inside line.

**Alternate Method: You may use card stock paper such as done with the sides to create a bottom template

8. Cut the CleanCut Step to fit the cut-out tub opening using a jigsaw (Figure 5).

Fasten Velcro-stripping on both sides of the jigsaw to prevent making any unwanted marks on the CleanCut Step. It is important that a 2” blade is used to cut out the CleanCut Step so as to prevent accidentally cutting through the top of the CleanCut Step. Snap off any excess length on the stock jigsaw blade beyond 2”.

FIGURE 5

USE THE JIGSAW TO CUT THE LINES TRACED ON THE STEP.

It is required that proper eye protection be worn while using the jigsaw. Cut directly on the center of the traced lines. Upon reaching the corners while cutting, tilt the jigsaw outward to prevent cutting past your lines on the vertical ends of the CleanCut Step. Remember to tilt your blade on each corner, cutting all areas that have been marked.

9. Place the CleanCut Step into position. Remember, the straight face of the

CleanCut Step is on the outside of the tub. Use a small pocket mirror and look for areas on the CleanCut Step that may be catching and prohibiting the

CleanCut Step from freefalling onto the tub. Use the jigsaw or drywall plane to trim the CleanCut Step where necessary.

10. Continue this process and repeat as necessary until a desirable close fit is achieved. The CleanCut Step should free fall onto the tub without catching or binding. Once final adjustments have been made, use a drywall plane or deburring tool (a common potato peeler works well) to clean up the remaining edges.

11. Having completed use of the jigsaw, take a moment to tidy the tub and work area.

Support Structure Installation

Once the CleanCut Step has been cut and a satisfactory fit into the tub opening has been achieved, it will be necessary to assemble the support box structure to provide support to the CleanCut Step. An example of the CleanCut Step and the support structure is illustrated in Figure 6.

The CleanCut Support box structure consists of one small and one large Support

Box. The large support box will compress over the top of the small box to the necessary height to provide support to the CleanCut Step.

CLEANCUT STEP

FIGURE 6

SUPPORT BOX STRUCTURE –

LARGE SUPPORT BOX

COMPRESSED ON SMALL BOX

BASE 2X4 AFFIXED TO FLOOR,

IF NECESSARY

It is important to understand that each tub has variations and modifications

maybe necessary in the field.

1. It may be necessary to adjust the Support Box structure according to the conditions present during your installation. For example, for wooden subfloors, begin by screwing or gluing a treated 2x4 directly to the sub-floor to serve as the base for our support structure. For concrete floors, a treated 2x4 is adhered directly to the concrete floor with adhesive. The 2x4 might need to be cut into several sections if there is a support brace in the cut out channel.

2. Build the Support Box structure to appropriate height. If working with a concrete sub-floor, thoroughly inspect and clean the floor in the tub cut out channel prior to securing the treated 2x4. Remove any materials from the concrete that may cause an uneven surface. Apply adhesive directly to the concrete floor. Insert the 2x4’s and thoroughly spread the adhesive on the concrete.

3. If wood sub-floor is present, screw the 2x4 directly to the sub-floor.

4. Prior to inserting the small Support Box, it is first necessary to secure a 22 ½” long 2x4 into the channel of the small Support Box. Place a bead of adhesive around the inside of the Support Box and insert the 2x4. Place several screws into the small Support Box to properly adhere the 2x4 into proper position.

FIGURE 7

Small Support Box

DRYWALL SCREWS HOLDING

2x4 (each side)

5. Insert the small box in the channel. At this point, do not adhere the small support box to anything. Place the large support box into the channel and over the top of the small box. Place the CleanCut Step into position and compress the CleanCut Step downward to determine the proper height and placement for the support box structure.

6. Once the support of the CleanCut Step has been achieved, remove the Step and mark both the left and right ends of the small box where the large box is compressed while the boxes are in the tub opening channel. Once properly marked, remove both support boxes and label the markings “Left” and “Right”

to avoid potential confusion. Uncompress the two support boxes from one another and begin the process to permanently adhere the boxes in proper position.

7. Apply adhesive around the perimeter of the large box. Compress the small and large support box structures back together to the appropriate markings made earlier on the small box. Place the support structure back into the channel and insert the CleanCut Step to verify that proper placement has been achieved.

Secure both sides of the support structure by placing two screws in each side

(Figure 8).

FIGURE 8

1 ¼” Dry Wall Screws

8. Apply adhesive to the tops of the 2x4’s that are already in place in the channel, if they are needed for height adjustment and insert the support box structure.

9. Place the CleanCut Step into position once more to inspect the fit and position.

This is the final opportunity to make any adjustments if necessary.

10. Apply adhesive to the top of the large support box. It is recommended that an extra bead of adhesive be placed on the ends of the large support box as the

Step curves up toward the ends. Place a substantial bead of adhesive on the top left and right side of the tub where the CleanCut Step will be seated. Adhesive on the top of the tub reinforces the CleanCut Step.

11. Prior to placing the CleanCut Step into the channel, it is necessary to gently pass a low flame several times along the perimeter of the cut out where the tub is met. This will help promote bonding between the step and the bath tub once adhesive is applied. Use caution when using the torch and do not hold heat on

12. Place the CleanCut Step into the channel and gently press into place. area of the product as it may discolor or melt.

Completing the Installation

1. Before finalizing the installation, first make sure the CleanCut Step is in proper position and fully compressed. Press firmly and evenly on the CleanCut Step to ensure proper placement. Thoroughly wipe the tub area with isopropyl alcohol where the adhesive will bond, and allow enough time to flash off before applying the adhesive. DO NOT apply the isopropyl alcohol directly on the adhesive as it will prevent the adhesive from drying or curing. DO

NOT use to clean or smooth your final bead as well.

2. It is necessary to caulk around the entire perimeter of the CleanCut Step. Begin by using the recommended adhesive along the sides of the CleanCut Step.

Begin on the left side and complete the process, before moving to the right side and bottom. It is recommended that you wear gloves during this step to avoid direct exposure to the adhesive.

3. Run your gloved finger along the beads and wipe the excess on a folded paper towel. Try to smooth the beads one-time only.

4. Underneath the bottom edges of the CleanCut Step are a bit more difficult to see and the angled tip should be used in completing this step. Use the small mirror to inspect the bead and to verify that all surfaces have been properly sealed.

5. It is also recommended to remove the stopper from the tub upon completion of the installation to prevent from accidentally filling the tub with water and, if desired, replace trip lever with a blank cap.

6. Spend a few minutes at the end of the job to once again clean up the tub and the bathroom area. Upon completion, place a sign on the CleanCut Step warning not to use the tub for 2 days while the adhesive cures.

IMPORTANT REMINDER - PLEASE LEAVE THE CUSTOMER PACKET

THAT INCLUDES WARRANTY REGISTRATION INFORMATION WITH THE

CONSUMER AT THE CONCLUSION OF THE INSTALLATION.

The CleanCut Step installation is now complete. CleanCut sincerely thanks you for your interest in the CleanCut Step and looks forward to assisting you in any way possible.

Visit our website at www.cleancutbath.com or call us toll-free at (877) TUB-STEP

(882-7837) with any questions or concerns you may have.