Instructions / Assembly

INSTALLATION INSTRUCTIONS
for Interior Door Slabs (JII110)
3
INSTALL SLAB - CONTINUED
3
2. If necessary to t
the existing jamb,
a maximum of 1/4"
can be trimmed
from each side of
hollow or solid
core molded and
ush doors only.
Trimming any
other type is not
recommend. 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 ne toothed
circular saw (height)
and wood plane
(width). Trimming
beveled edges may
require re-beveling.
3. The latch stile may
have a pre-cut 2˚ or
3˚ bevel. This bevel
maintains a 1/8"
clearance between
the jamb and latch
edge and improve
the t when the
slab is closed. If
the latch stile is
not beveled, and a
bevel is preferred,
use a wood plane
or ne-toothed
saw to cut a bevel
so that the slab
face that rests
against the stop
becomes slightly
narrower than the
oppositeface.
TEST SLAB FIT IN JAMBS
Before installing any
hardware, t the
slab in the frame
and verify it will t
properly. Looking at
the hinge side of the
slab when it is closed,
there should be 1/16"
gap between the
slab and hinge jamb
and1/8" between the
slab and the head and
strike jamb.
Bottom
rail
Stile
1/4"
1/4"
1/4"
Top rail
Trim-able
portion
Trim-able
portion
Slab
Bevel
Stop
1/16"
1/8"
1/8"
INSTALL HINGES
1. Three hinges are recommended for slabs up to 84" in height and four
hinges for slabs over 84".
2. If re-using existing
jambs, verify the
existing hinge
locations are plumb,
or all in a straight line
vertically. Position
the new hinges in
the existing locations
and modify the
mortises as necessary.
Match the slab to
the jambs using the
followinginstructions.
3. If installing new
jambs, measure down
from the underside of
the top of the jamb
7" to position the
top of the top hinge.
Measure up from the
bottom of the slab 10"
to position the bottom
of the bottom hinge.
Place the middle hinge
halfway in between.
4. When marking the
slab for hinges, make
sure the measurement
from the top of the
slab to the top of
the hinge route is
1/8"smaller than the distance from the head jamb to the top of the
top hinge. This will allow 1/8" gap between the slab and head jamb.
5. When marking the
slab, the distance from
the inside face to the
back of the hinge
route should be 1/16"
less than the depth
of the hinge route on
thejamb.
6. Using a template,
mark the jambs and
slab where the hinges
will be mounted.
Using 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. Using the hinge as a template, mark screw hole locations and drill
pilot holes for all screws. If possible, it may be easier to remove the
hinge pin to separate the hinge leaves. Use a hammer and a punch to
drive the pin from the open end. Install the hinge leaves separately
on the jambs and slab (we recommend using a hand screwdriver
when installing screws into the slab to prevent stripping). Then, hang
the slab in the frame by aligning the hinge leaves and re-install the
hinge pins.
6 7/8"
7"
Plumb
line
3/16"
1/4"
Slab
Hinge
jamb
Stop