Instructions / Assembly

10/01/18
Installation Instructions
for Interior Door Slabs (JII110)
4
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.
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.
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"
3/16"
1/4"
Slab
Hinge
jamb
Stop
6 7/8"
7"
Plumb
line