JELD-WEN JII107 Exterior Door Slabs - Manual (Page 3)

INSTALLATION INSTRUCTIONS
for exterior Door Slabs (jii107)
3
inSTALL SLAB - COnTinUeD
3
TRIMMING ALLOWANCE- FOR WOOD DOORS ONLY
1. if necessary to
fi 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 fi 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 fi t when the
slab is closed. if
the latch stile is
not beveled, and a
bevel is preferred,
use a wood plane
or fi 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, fi t the
slab in the frame
and verify it will fi 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. 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.
6 7/8" 7"
Plumb
line
3/16" 1/4"
Slab Hinge
jamb
Stop