Instructions / Assembly

INSTALLATION INSTRUCTIONS
for Exterior Door Slabs (JII107)
3
IMPORTANT: The door slab should be finished (painted or stained) on
all six sides with an equal number of coats after all routing, trimming,
boring and touch-up has been completed and it has been properly fit
in the jamb. Failure to finish on all six sides and install into a square,
level and plumb condition could result in denial of warranty claims for
operational or performance problems. See our finishing document at
www.jeld-wen.com for finishing requirements and details.
PREPARE JAMBS AND SLAB
1. Measure the existing
frame (not the stop)
from the top of the
threshold to the
bottom of the head
and from side to side
in several places to
verify the slab will t.
The frame should be
3/16" wider than the
slab (1/16" clearance
on the hinge jamb
and 1/8" clearance
on the strike jamb)
and tall enough
(usually 5/8" taller) to
allow 1/8" clearance on the head jamb and 1/2" between the bottom
of the slab and the top of the threshold.
TRIMMING ALLOWANCE- FOR WOOD DOORS ONLY
1. If necessary to
t the existing
jamb, a maximum
of 1/4" can be
trimmed from each
side. 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.
2. 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.
Frame/stop
Weatherstrip
INSTALL SLAB
3
Bottom
rail
Stile
1/4"
1/4"
1/4"
Top rail
Trim-able
portion
Trim-able
portion
Slab
Bevel
Stop
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.
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. Fill and
re-drill screw holes if
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 (not the stop)
7" to position the top of
the top hinge. Measure
up from the top of the
threshold 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. Then, hang the slab in
the frame by aligning the hinge leaves and reinstall the hinge pins.
1/16"
1/8"
1/8"
6 7/8"
7"
Plumb
line
3/16"
1/4"
SlabHinge
jamb
Stop