Prerequisites
Structural Opening:
- Nibs are required on either sides of the door
- The structural opening can be unfinished
- Take note of the minimum and maximum tolerance for width & height (see drawing)
- Opening sizes depend on door size (see drawing)
Equipment
- Craft knife
- Screw driver
- Level
- Tape measure
Check Box Content
Receive boxes and place on level surface and open box. Check contents of box for the following:
- Door
- Lock set
- Striker
- Handles
- Cylinder or Knob cylinder
- Hinges
- Screws
- Wedges
- 3mm Spacer pieces
- Dowels
- Frame top, rail & stiles
- Architraves
- Expandable foam
- Instruction manual
Frame Assembly
Work on a flat and smooth work surface. Take care not to damage the frame or door!
- Assemble the frame with screws on each side
- Screw hinges to the frame
- Insert the striker plate into the pre-drilled recess of the frame and screw tightly with provided screws
Marking of Hinges
Remove the door from the box
- Place the door in the frame
- Insert 3mm spacers on all sides of the door between the door and the frame
- Mark position of the hinges on the door, 1½ hinge lengths, or 150mm from the top of the door
- Remove the door from the frame
Installation of Frame
Insert frame into structural opening.
- Insert 2mm spacer below door frame
- Secure frame in structural opening with top wedges only
- Insert door into opening with 5mm spacer below door
- Screw hinges into door
- Insert lockset into door
- Install handles and cylinder or knob cylinder
- Check that the striker and lockset line up
- Place door in closed position and insert 3mm spacers on all sides of the door, between the door and the frame.
- Make adjustments to frame with wedges and ensure door and frame are plumb and aligned with wall
Spacing the Door
- Remove 3mm spacers and check that the door opens and closes correctly
- Re-insert 3mm spacers above and on the sides of the door
- Re-insert 3mm spacers between the top and bottom hinge
- Re-insert 3mm spacer on striker side of door
Foaming the Door
- Insert foam all around the door frame
- Be careful not to apply too much foam as the foam expands.
- Allow foam to dry completely (allow for a drying time of at least 2 hours before opening the door or moving the wedges)
- Move on to the next door while the foam dries
Architraves
- Once foam is completely dry remove the 3mm spacers and the wedges
- Trim off any excess foam
- Insert architraves on both sides