Installing a Solid Vinyl Door

Beyond The Screen Door inspects and tests each door to ensure a proper fit in the frame before it leaves the plant. These instructions will help you ensure the proper installation for smooth operation.

The solid vinyl material requires no further finishing. The color will not fade and the material resists scratches, dents and chips. DO NOT PAINT your door, as the paint will not adhere to the finished vinyl surfaces.

To maintain the look of your door, simply clean periodically with plain soap and water.

A) Before you begin

Be sure to check the following:

Measure your door opening and check it with the sizing chart below to ensure you have the correct door size. Measure the width in three places and the height in two as shown, and use the smallest measurements to determine your opening size.

If your door opening does not fit any sizes in the chart, you may have to order a custom-sized door or have a professional carpenter modify your doorjamb.

The installation is much easier if you have a helper. Give the door time to adjust to the outside temperature before you start.

Decide which way your door will swing - usually the screen door is hinged on the same side as the main door.

You will need these tools:

• Power drill with 1/8" and 5/16" bits and Robertson screwdriver #8 bit
• Robertson screwdriver (red handle)
• Phillips Screwdriver (cross shaped)
• Straight Screwdriver
• Hammer
• Hacksaw
• Level
• Tape measure
• Framing Square
• Pencil
• Pliers

B) Hanging the Door

1. Install Drip Cap (Header Z-Bar)
   Position the drip cap on top of doorframe and center it with an even space on both sides, as shown. Fasten in place on the hinge side only with a #8 x 1" screw.
   
   
2. Cut and install hinge-side Z-bar on door
   Measure the length from the underside of drip cap to the top of your door sill. Check to be sure the hinge-side Z-bar is right way up by holding it roughly in place, then cut the bottom to length with a hacksaw. If your door sill slopes away, you may want to cut to this angle. Have your helper hold the door on its edge and place the Z-bar on it as shown. Make sure you are placing the Z-bar on the edge you have chosen as the hinge side. Allow the Z-bar to extend 1/8" past the top of the door. Center the hinges in the hinge groove on the door's edge and fasten the Z-bar with #8 x l" screws. The screws and the hinges will self center themselves in the groove on the back of the door.
   
   
3. Place door in opening
   Stand the door so that the hinge-side Z-bar is even with the end of the drip cap and is pushed tight to the underside of the drip cap. To prevent splitting the material, drill a 1/8" pilot hole through the top mounting hole in the Z-bar, into the brick mould. Secure the Z-bar with one #8 x 1 1/4" screw. If your door opening is at the upper limits of the tolerances shown in the sizing chart, you may need to secure shims between the doorjamb and the Z-bar. After measuring, remove the door from the opening and secure the required shims to the brick mould. Return the door to position and replace the #8 screw. Ensure the Z-bar is straight and vertical with a level, then secure it with the #8 x 1 1/4" screws. Remember to drill l/8" pilot holes to prevent splitting. Open and close the door to check that it swings freely and does not bind. With the door open, drill 1/8" pilot holes through the mounting holes on the inside edge of the Z-bar just above and below the hinges. Install the eight #8 x 1 1/4" screws taking care not to over tighten. If you have over tightened, and the Z-bar bends, back the screws out slightly until the Z-bar springs back into position.
4. Level and Secure Drip Cap
   Slightly loosen the screw holding the drip cap in position on the hinge side. Adjust the drip cap until an even gap appears between the drip cap and the top edge of the door. Drill pilot holes through the drip cap and secure to the door frame with #8 x 1 1/4" screws.
5. Cut and Install Latch Side Z-bar
   Measure from the bottom of the drip cap to the top of the sill on the latch side. If your door sill is sloped you may want to cut the Z-bar to match this angle. Be sure the Z-bar is right side up, as with the hinge-side, then cut to length with a hacksaw. Position the Z-bar on latch side, allowing a 1/8" to 3/16" gap to show between the door and the Z-bar. Drill 1/8" pilot holes through the mounting holes and secure with #8 x 1 1/4" screws. Place plastic finishing caps on the screw heads of the exposed screws.

With the door in place, you can now install the lockset and closer hardware. Instructions are included in the hardware packaging, or follow the hardware instructions here.

CAUTION: BEFORE YOU PROCEED WITH HARDWARE INSTALLATION, MAKE SURE THAT THE INSIDE OF LATCH WILL NOT INTERFERE WITH THE MAIN DOOR HARDWARE.