WOOD-CORE Overlap with Rectractable Screen Installation Instructions Before You Get Started....................................................Page 1 Installation Instructions....................................................Pages 2-5 Closer Installation Instructions ........................................Pages 6­7 Troubleshooting ...............................................................Page 8 General Care and Maintenance........................................Page 9 Warranties ........................................................................Page 9 Visit our web site at www.larsondoors.com 202220574 LM 8/04 Congratulations! You've purchased a quality-built wood core storm/screen door from Larson. Please take a moment to fill out and mail in your product warranty card for years of trouble-free service. See page 11 for warranty details. NOTE: Modification of door will void warranty. Retain instruction booklet and sales receipt for future reference. If you have any questions regarding the installation of your Larson storm door or need to order replacement parts, don't go back to the store, call our Homeowner's Helpline at 1-888-483-3768. Our staff of storm door experts are on hand to answer any questions you may have. Please have the following information on hand when you call: (1) Warranty Registration number--the number is on a decal located on the hinge z-bar (door must be open to view once installed) (2) Model of door (3) Opening size of door (4) Color. CAUTION: READ THE WARNING BELOW BEFORE INSTALLATION. 1. The door requires caution while installing and during its total operational life. 2. The door is heavy and requires two people to lift and install on your home or business. 3. Pinch points are indicated in the instructions by this symbol. Children should not be allowed to play with the door and should be made aware of the pinch points by the owner. Failure to properly instruct the user of this product could result in the loss of a finger or other injury. 4. Do not operate the storm door without closer(s) installed and adjusted to prevent door slamming. 5. Eye protection must be used during the installation to prevent damage from flying particles. 6. Do not modify or alter the installation and specified use of the door. 7. Read the complete installation instructions before proceeding with installation. NOTE: Larson Manufacturing Company is not responsible for accidents and injury resulting from the use or installation of this product. FIGURE 1 TOP Z-BAR OR DRIP CAP PARTS IDENTIFICATION TOOLS NEEDED 1. Power drill with bits (5/16", 1/8", 3/32") 7. Hammer 2. Phillips head screwdriver, 8. Pencil regular screwdriver 9. Pliers 3. Hacksaw 10. Saw horses 4. Caulking gun with caulking (optional) 11. Small wood chisel 12. Hole Saw or spade 5. Tape measure 6. Square and level drill bit (per hardware instructions) PINCH LATCH SIDE Z-BAR HINGE SIDE Z-BAR PINCH Larson recommends having another person help you install your wood core storm door. A cordless drill with a screwdriver bit is recommended. Assembly may require shimming to fit existing opening (shims not included). BEFORE YOU GET STARTED ® ® ® ® ® Verify opening size with size shown on the box label. Remove hardware box from inside door carton. Remove the expander from the door (will be applied later). See Figure #1 House door trim must be securely nailed to support your new storm door. Check box for any INSTRUCTION REVISIONS (printed on colored paper). Instruction revisions take precedence over printed manual. PINCH FRONT VIEW PINCH PINCH EXPANDER AND VINYL SWEEP 1 FIGURE 2 Determine Left or Right Hinge Side LEFT HAND HINGE RIGHT HAND HINGE Your Larson storm door is Reversa-HingeTM meaning that the door is designed for either right hand or left hand hinge installation. Looking at your door opening from the outside, determine which side you want the hinge on. IMPORTANT NOTICE: If you choose to have the storm door handle on the same side as your prime door hardware, you MUST verify that there will be NO interference between the two handles or hardware. NOTE: Sash is operated from inside of door. 2 Install Hinge on Door FIGURE 3 OUTER FRONT FACE OF DOOR ­ UP START TOP OF SCORE LINE DOOR HINGE LEAF TURNED DOWN The "hinged Z-bar assembly" (or hinged door frame) is packaged unattached. It can be mounted to either side of the door. Lay the door flat on saw horses with the outer front face of door facing up. Place the "hinge Z-bar assembly" on the edge of the door as shown with each hinge leaf turned down (Figure 3). Check to see that the aluminum Z-bar is oriented as shown in illustrations (Figure 4 for a left-hand hinged door, or Figure 5 for a right-hand hinged door). Move "hinge Z-bar assembly" up or down until the top of the Z-bar hangs over the top edge of the door 1/16"­1/8" (Figure 6). Mark the top hole of the top hinge and drill an 1/8" pilot hole. Install one #8x1" unpainted pan head screw (Figure 7). NOTE: You must use a screwdriver with a long shaft due to the difficult angle of z-bar. The top end of the Z-bar MUST overhang the top of the door 1/16" to 1/8". The bottom end will be cut to length later. Align each hinge leaf along the edge of the door. Mark holes, remove hinge z-bar then drill 1/8" pilot holes, making sure holes are located on the score line. Reapply hinge side z-bar and align with holes. Complete the attachment of each hinge to the door using the remaining #8x1" unpainted pan head screws. NOTE: Hinged Z-bar must swing after securing hinges to the door. Rotate per Figure 3. FIGURE 4 FIGURE 5 ROTATE SCREWDRIVER WITH LONG SHAFT INSTALLED POSITION END VIEW 1/8" PILOT HOLES NEEDED OU FA TER CE ­F OF RO DO NT OR TOP OF DOOR HINGED Z-BAR ASSEMBLY FIGURE #3 END VIEW LEFT EDGE OF DOOR 1/8" PILOT HOLES NEEDED RIGHT EDGE OF DOOR NT RO R ­F OO ER F D T OU CE O FA TOP OF DOOR HINGED Z-BAR ASSEMBLY FIGURE 6 1/16"-1/8" FIGURE 7 #8 x 1" PAN HEAD SCREW HINGE Z-BAR TOP CORNER OF DOOR 2 WOOD-CORE OVERLAP RS 202220574 3 FIGURE 8 Measuring the Opening Facing the house from the outside, measure the height of the opening as illustrated in Figure 8. This measurement is taken from the top of the door opening (underside of the trim board) down to the bottom threshold. Take two measurements (A and B) as shown to determine the threshold angle to cut the Z-bar. B A ATTENTION: If your opening height is 80-3/4 to 81" For best results, we recommend you install a 1/4" shim at the top of the opening (Figure 18). 4 Cut Hinge-Side Z-Bar to Length A The top of the z-bar should be at the correct position--1/16" to 1/8" above the door. The bottom of the z-bar must be cut to the correct length (opening height), taking into account the angle of the threshold (Figures 9­11). Using the measurements taken in step 3, determine the angle to cut the z-bar. Transfer this measurement to the z-bar, measuring from the bottom of the notch at the top--down to the cut line (Figure 12). NOTE: You must measure from the bottom of the notch or you will cut the z-bar too short. Now make a cut 1/16" less than your measurement to allow room for top drip cap. Save the z-bar cut-off scrap for steps 6 and 9. B HINT: Measure twice. Cut FIGURE 9 TOP OF Z-BAR FIGURE 10­11 FIGURE 12 1/16 ­ 1/8" OVERHANG BOTTOM OF NOTCH OPENING HEIGHT OPENING HEIGHT (UNDERSIDE OF DRIP CAP TO TOP OF SILL) CUT LINE CUT LINE CUT LINE BOTTOM CUT 202220574 WOOD-CORE OVERLAP RS 3 5 Install Expander Sweeps FIGURE 13 EXPANDER NOTE: This does NOT apply to models with vinyl expanders. Vinyl expanders have integrated sweeps. Remove the expander from the door if you haven't already. Some models come with a single sweep, others come with a double sweep. To install the sweep, simply thread the sweep into the channel of the expander. With the sweep installed, crimp both ends of the expander channel with a pliers. NOTE: For best results crimp the inner leg of the channel­only, at both ends of the expander (Figure 13). FOR THE DOUBLE SWEEP ONLY: You must bend the rubber sweep out of the way while crimping. CRIMP (INNER LEG) DOUBLE SWEEP EXPANDER CRIMP (INNER LEG) SINGLE SWEEP 6 Secure Door to Opening FIGURE 14 Place the door in the opening with the hinge-side Z-bar tight against the door trim or wood frame. Temporarily install just two of the painted #8 x 1" pan head screws (Figure 15) on the front of the hinge-side Z-bar. Install one screw next to the top hinge and one next to the bottom hinge. Be sure not to over tighten the screws and crush down the Z-bar. Set the cut-off scrap piece of Z-bar in place between the door and up against the wood trim on the latch side of the door as shown in Figure 14. From the outside of the house with the door closed, check the alignment of your Larson storm door and the scrap Z-bar. A wood spacer can be placed between the hinge-side or latch-side Z-bar and the wood jamb if desired alignment can't be achieved by sliding z-bar side to side (Figure 17). If a wood spacer is needed, remove the door, add the spacer and reinstall. Spacer thickness should not exceed 1/4" and longer screws should be used to properly secure the door to the jamb. NOTE: Wood spacers and longer screws are not included. TOP VIEW SCRAP Z-BAR BRICKMOLD SIDE STILE OF STORM DOOR APPROX. ALIGNED FIGURE 15 FIGURE 16 #8 X 1" PAN HEAD PAINTED #8 X 1" FLAT ZINC PLATED FIGURE 17 7 Secure Hinge-Side Z-Bar INSTALLED POSITION With the door properly fit in the opening, open the door to expose the hinges. You will see two (2) pre-punched holes at each hinge plate. Using eight (8) #8x1" flat head screws (Figure 16), attach each hinge plate to the wood jamb. Screw heads must be flush with the hinge surface. Install the remaining #8x1" painted pan head screws (Figure 15) in the outside of the hinge-side Z-bar. WOOD SPACER 8 FIGURE 18 Install the Drip Cap DRIP CAP The drip cap goes above the door and z-bars. Place the top drip cap into position as shown in Figure 18. Close the door. The drip cap notch and the z-bar notch should nest together for a good fit. Allow 1/16"­1/8" gap between the drip cap and the top of the door. The door should close freely without hitting the drip cap, but also make good contact with the weatherstripping. Attach the drip cap with the #8x1" painted pan head screws provided (Figure 15). If needed, a shim can be added between drip cap and brickmold for a tighter fit (Figure 18). 1/4" SHIM (IF HEIGHT IS 80-3/4"­81") TOP RAIL OF STORM DOOR 4 WOOD-CORE OVERLAP RS 202220574 9 Install Latch Side Z-Bar Determine Top: First, determine which end of the Z-bar is top and mark it with a piece of tape. Bottom Cut: Cut the Z-bar to length (use the same procedure used to cut the hinge side Z-bar back in Step 4, page 3). Remember to measure from the bottom of the notch. Installation: Set the Z-bar in place between the door and wood jamb. Allow a 1/16" to 1/8" gap between the door and the latch side Z-bar. Make sure the door closes freely without hitting the Z-bar, but also makes good contact with the weatherstripping. Refer to Figure #14 for approximate z-bar to edge-of-door alignment. Using #8x1 painted panhead screws (Figure 15), fasten Z-bar through the pre-drilled holes provided. Larson offers three types of z-bars. The style will vary based on the handle set of your model. · Surface-mount Figure 16 · Mortise with deadbolt Figure 17 · Mortise without deadbolt Figure 18 FIGURE 16 SURFACE MOUNT FIGURE 17 MORTISE WITH DEADBOLT FIGURE 18 MORTISE WITHOUT DEADBOLT MORTISE HOLE COVER OPENING HEIGHT OPENING HEIGHT OPENING HEIGHT Install the Mortise Hole Cover on the hinge-side edge of door to cover up hole. CUT LINE CUT LINE CUT LINE CUT BOTTOM OF Z-BAR ONLY. LEFT HINGE APPLICATION SHOWN. CAULKING may be applied, although not always necessary. Apply caulking behind the latch, hinge and top Z-bars, or along the front edge of Z-bar. LEFT-HINGE Z-BARS SHOWN ABOVE. 10 Install Latch Hardware 11 Install and Adjust Bottom Expander Refer to separate instructions packaged in the hardware box. Install expander at the bottom of the door with the slotted holes to the inside. Adjust the bottom expander so that the vinyl sweeps touch the door threshold. Centrally locate the two #6x3/8" pan head screws in the slot to allow for future adjustments. Drill 3/32" diameter pilot holes for the screws, being careful not to drill all the way through to the front face of the door, then install screws. #6 x 3/8" PAN HEAD STAINLESS 202220574 WOOD-CORE OVERLAP RS 5 Wood-Core Overlap Series Storm/Screen Doors CLOSER INSTRUCTIONS 1 Closer Installation CLOSER ASSEMBLY INSTALLATION: NOTE: Be sure door opens and closes freely before installing the closer. TWO CLOSER MODELS 1. To install the top closer, hold closer assembly 1-1/2" above door window and hold jamb bracket 1/4" back from storm door (Figure 1). Mark jamb bracket holes and two holes in door bracket. 2. Fasten ...