Storm Doors – Installation

1. Your door package should include the following items: Door slab with glass and screen inserts; 1 set of Z bars including 1 hinge rail and 1 latch rail; 1 header; 1 door expander (attached to the bottom of the door); 1 package of hinge and jamb screws (packaged inside the door expander); 1 package of installation screws painted to match door color (packaged inside the door expander); 1 package of clear polycarbonate clips & screws to hold glass and screen inserts (packaged inside door expander). Note: Self Storing models do not require polycarbonate clips. Before unwrapping the door, stand the door up in the opening to make sure it is the proper size. The following chart shows the minimum and maximum openings that a standard size door will fit. The minimum and maximum opening refers to the measurement between the brick mold or casing on the outside of
   the entry door.

STANDARD
DOOR SIZE	ACTUAL SIZE	MIN. OPENING	MAX. OPENING
30" width	29 3/16"	29 5/8"	30 1/4"
32" width	31 3/16"	31 5/8"	32 1/4"
36" width	35 3/16"	35 5/8"	36 1/4"
80" height	79 3/16" w/expander	79 1/2"	80 3/4"



2. After checking for correct size, cut the banding around the door to remove the glass & screen inserts. Be careful not to let the inserts drop out. The screen is taped at the top of the door. Remove the tape to remove the screen, then take the glass out of the door. Note: Self-storing styles do not require removing glass and screen, but removing them will make the door easier to install.
3. Determine the hinge side and latch side by standing on the outside facing the door. Then lay the door on its edge, latch side down, to install the hinge rail. Position the hinge rail on the edge of the door so the hinge leaves interlock with the edge of the door. Make sure the top of the hinge rail is 1/16" beyond the top of the door. Attach the hinge rail to the hinge side of the door using the short unpainted #8 screws. Using an 1/8" drill bit, drill holes and install 2 screws in each hinge leave. (See Figure 1)
4. Measure the opening height on the hinge side of the entryway, then subtract a 1/4". Cut the bottom end of the hinge rail to that size. Crimp the end of the hinge rail to prevent the weather stripping from sliding out.
5. With the hinge rail attached, mount the door in the center of the opening. Be sure to leave 1/4" clearance at the top of the hinge rail to allow for the header rail. Using a painted screw, attach the hinge rail to the door frame. Check to make sure the hinge rail is straight and plumb, then using an 1/8" drill bit, drill holes and use 5-6 painted screws to attach the hinge rail completely. Note: Don’t worry if the hinge rail does not fit flush against the opening.
6. Open the door and install the unpainted 1 1/4" #8 screws through the pre-drilled holes on the inside face of the hinge rail. Space behind the hinge rail may be shimmed but is not necessary. Do not over-tighten these screws as they may prevent the door from operating properly.
7. Check the hinge rail for binding by opening and closing the door. The door should close smoothly and remain closed if it is adjusted correctly. If the door springs out and will not remain shut, adjust the 8 screws in edge of the hinge rail to eliminate any binding. If the door is not plumb you may rack or “bend” the door to fit the opening.
8. Position the header rail at the top of the door. The header rail will sit on top of the hinge rail and align with it. Close the door and install header rail, allowing approximately 1/16" clearance across the top of the door. (See Figure 8) Using an 1/8" drill bit, drill holes through the header rail and fasten the header rail to the door frame with 3 painted screws. Crimp the ends of the weatherstrip groove with a pair of plyers.
9. Measure the opening height on the latch side of the entryway then cut the latch rail from the bottom to that size. Note: If your entryway threshold is sloped on an angle, be sure to cut the bottom of the latch rail on an angle to match the threshold. Crimp the ends of the weatherstrip groove in the latch rail so the weatherstrip won’t move.
10. Position the latch rail in the opening. The top of the latch rail should butt up against the header rail. Close the door and adjust the latch rail to maintain a 1/8" reveal between the door and the latch rail. Using an 1/8" drill bit, drill holes and screw the latch rail to the door frame with 5 or 6 painted 1" screws.
11. Install the black sweep in the adjustable sill expander by pushing it through the groove in the bottom of the expander. Secure the sweep by crimping each end of the groove with a pair of pliers.
12. Install the sill expander on the bottom of the door. Close the door and adjust the expander so the sweep is just touching the sill and not binding. Install two more painted 1" screws in the slots on the inside face of the expander.
13. Install hardware per manufacturer’s instructions found in hardware box.

FRENCH DOORS (Double doors)

1. Use the same procedure above, allowing approximately 1" between the doors for installation of the astragal (center bar).
2. The astragal should be mounted to the edge of the inactive door, overlapping the bottom expander. The two aluminum slide bolts are attached on the inside of the astragal at the top and bottom.
3. The latch will cover the edge of the astragal (a strike plate is not needed). The edge of the weatherstrip groove can be pinched or opened to adjust for latching action.