Therma Tru Door Hinged Patio Door System Single Panel Assembly Unit User Manual

DOOR  
PATIO  
SYSTEMS  
Therma-Tru®  
Hinged Patio  
Door System  
Single Panel  
Unit Assembly  
Read all instructions before starting.  
The applicable standards for these products are governed by  
the International Residential Code.  
Copies of performance ratings and testing are available on our website  
 
Part identification - continued  
#6 x 3/4”  
flat head screw  
#10 x 3/4”  
flat head screw  
#8 x 5/8”  
flat head screws  
#8 x 3/4”  
flat head screw  
#8 x 1-1/4”  
flat head screw  
#8 x 2”  
flat head screw  
#8 x 3/4”  
wafer head screw  
#10 x 2-1/2”  
flat head screw  
Tools/materials required  
This is a listing of tools that may be required to assemble unit.  
• Drill/screw gun  
• Phillips head drive bit or screwdriver #2 & #3  
• Silicone sealant and caulk gun  
• Utility knife  
• Rubber mallet  
• Hammer  
• Staple gun with 1/2” x 7/16” crown staples  
• 3/32” & 1/8” dia. drill bit  
• (2) 2 x 6 boards - 38” long  
2
 
NOTE:  
A large work area is needed to assemble the frame kit. Cover area with  
cardboard from one or more door panel cartons to protect frame parts  
and floor. If available a carpeted table can be used to avoid marring  
prefinished surfaces.  
REMOVE COMPONENTS FROM PACKAGING  
1
2
NOTE:  
Product that is purchased with the multi-point lock system will have additional  
instructions in the handle hardware box.  
Installation instructions will be included in the site package.  
ATTACH HINGES TO DOOR  
Standard Hinge Option  
Use Correct Hinge Leaf  
Leaves applied to door have 2 knuckles.  
Leaves applied to jamb have 3 knuckles.  
2-knuckle  
door leaf  
with tabs  
3-knuckle  
jamb leaf  
Align and Install Hinges  
Place tabs firmly against door.  
Fasten 2-knuckle hinge leaves  
with #10 x 3/4” flat head screws.  
Place hinge  
tabs firmly  
against door.  
#10 x 3/4”  
NOTE:  
Right-hand  
application  
shown  
Outswing packages come with a  
non-removable pin (NRP) hinge.  
It is recommended to attach the  
hinge in the middle location. For  
8’ heights, two NRPhinges are in-  
cluded. NRP hinges have locating  
tabs. Fasten to door panel using  
same method as for unassembled  
hinges, placing tabs against door  
face to locate hinge.  
Rotate to  
opposite  
side for  
left-hand  
application  
Non-removable  
Pin Hinge  
3
 
ATTACH HINGES TO DOOR - continued  
2
Adjustable Hinge Option  
“H” marked hinge shown  
Marking  
Attach hinge to door  
Locate the “H” and “V” markings on hinges.  
The two “H” hinges go in top and bottom  
locations with the “V” hinge in the center.  
For 8’, the “V” hinge is located second from  
top of door.  
Insert thick side of hinge into pocket in door  
and fasten with #8 x 1-1/4” flat head screws.  
NOTE:  
Inswing hinges are reversible by  
removal of hinge pin. Outswing  
hinges are reversible by removal  
of set screw then removal of  
hinge pin.  
#8 x 1-1/4”  
INSTALL DOOR BOTTOM  
3
NOTE:  
Interior  
side  
of  
Outswing units do not  
require door bottoms.  
door  
Caulk and Fasten Door Bottom  
Select a sealant that provides excellent  
adhesion to both plastic and wood.  
Apply sealant as shown to ends of  
door bottom.  
Center door bottom and press into  
rail kerfs.  
Sealant  
Secure each end of door bottom with  
(1) #8 x 3/4” wafer head screw.  
#8 x 3/4”  
wafer head  
4
 
INSTALL WEATHERSTRIP  
4
Apply Weatherstrip to Active Frame Parts  
Press in kerf with hand.  
Head Jambs  
Align starting end with  
head gain.  
Fit and secure in place  
along full length.  
Long Reach  
Trim finish end flush with  
end of jamb.  
Head Jamb  
Hinge Jambs  
Align starting end with  
head gain.  
Short Reach  
Fit and secure in place  
along full length.  
Hinge Jamb  
Lock Jambs  
Align starting end with  
head gain.  
Long Reach  
Fit and secure in place  
along full length.  
Lock Jamb  
Trim Bottom End  
3/8"  
11/32”  
Trim weatherstrip  
as shown.  
Outswing  
Inswing  
5
 
INSTALL STRIKES  
5
Standard Strike Option - Inswing  
Adjustable  
security  
backing  
plate  
NOTE:  
Outswing units will have strike  
installed during unit installation.  
Slide Strike Assembly onto Lock Jamb  
Lock  
jamb  
Lightly bend tongue area of backing plate  
inward to allow for a snug fit then slide  
over edge of lock jamb into mortise.  
Fasten Security Strike  
Assembly to Lock Jamb  
(2) #9 x 3/4” flat  
head screws  
or  
(2) 16 gauge  
1/2” x 7/16”  
crown staples  
Fasten with (2) #9 x 3/4" flat head  
screws or (2) 16 gauge 1/2" x 7/16"  
crown staples (not supplied) through  
strike plate on back side of jamb.  
NOTE:  
Do not staple through screw holes  
when using staples in place of  
screws.  
(7) #8 x 5/8”  
flat head  
screws  
Multi-point Lock Option  
Fasten Strike Plates to Lock Jamb  
Fit strike plates into mortises on lock jamb.  
Pre-drill 3/32” dia. pilot holes through jamb.  
Fasten with (7) #8 x 5/8” flat head screws.  
CAUTION:  
Do not over torque screws.  
#8 x 5/8”  
6
 
ATTACH HINGES TO JAMB  
6
NOTE:  
These are instructions for installation of standard hinges. Proceed to  
step 7, FRAME ASSEMBLY, if using adjustable hinges.  
Standard Hinge Option  
Leave Holes Vacant  
Fasten Hinges to Hinge Jamb  
Place hinges into hinge mortise.  
Pre-drill 1/8” dia. pilot holes through  
jamb.  
Fasten top hinge with (2) #10 x 3/4”  
flat head screws in hole locations  
shown.  
Fasten middle and bottom hinges  
each with (3) #10 x 3/4” flat head  
screws leaving top hole vacant.  
#10 x 3/4"  
flat head  
screws  
CAUTION:  
Do not over torque  
screws.  
#10 x 3/4”  
7
 
FRAME ASSEMBLY  
7
Fasten Side Jambs to Head Jamb  
#10 x 2 1/2”  
flat head  
screws  
Butt and align head jamb to side jambs.  
Pre-drill 1/8” dia. pilot holes through side  
jamb into head jamb.  
Fasten side jambs to head jamb with  
(3) #10 x 2 1/2” flat head screws through  
lock and hinge jamb into head jamb.  
Inswing Sill Option  
Apply End Seal Pads  
End seal pad  
Remove from paper backing and  
apply adhesive side of end seal  
pads at bottom of each jamb.  
Sealant  
Caulk Entire Sill Gain  
Apply a 1/4" bead of sealant to sill  
gain and a bead that matches profile  
of sill.  
Match profile of  
fixed portion of  
sill. Leave areas  
of adjusting riser  
free of caulk.  
Fasten Sill to Side Jambs  
Fit and align sill between lock and hinge jamb.  
Starting approximately 3/4” from interior side  
of jamb, drill (3) 1/8” dia. pilot holes through  
each jamb into sill substrate.  
3/4"  
Fasten each jamb to sill with (3) #10 x 2 1/2”  
flat head screws.  
2 ½" flat head  
screws  
8
 
FRAME ASSEMBLY - continued  
7
Outswing Sill Option  
Partially Set Sill Screws  
in Jambs  
Drive (1) #8 x 2” flat head  
screw through holes in both  
side jambs until tips barely  
protrude through jamb face.  
Flat head screw  
#8 x 2”  
Caulk Entire Sill Gain  
Apply a 1/4” bead of sealant  
to sill gain and a bead that  
matches upper profile of sill.  
Sealant  
Fasten Sill to Jamb  
Use screw points and index sill in place.  
Drive screws using bit sized properly for  
screw head.  
Pre-drill (2) 3/32” dia. pilot holes through  
each jamb into sill substrate.  
Drive (2) #8 x 2” flat head screws through  
each side jamb into sill substrate in locations  
approximately as shown.  
9
 
FLANGE INSTALLATION  
8
Inswing  
Outswing  
NOTE: Inswing application shown.  
Align and Install Side Flanges  
Align edge of side flange with bottom  
of side jambs.  
Firmly press into kerf in jamb using  
a rubber mallet if necessary.  
Align  
Flange will be set back approximately  
1/2” from top edge of jamb.  
Install Top Flange  
Center top flange into head jamb  
kerf and press into place using  
a rubber mallet if necessary.  
10  
 
DOOR INSTALLATION  
9
Standard Hinge Option  
Make 2 “Insert Skids”  
38"  
2"  
Make from 2 x 6 boards.  
3"  
For 6-9/16" jambs  
For 4-9/16" jambs  
12-1/8"  
3/8"  
NOTE:  
It is recommended  
to cover skids with  
cardboard or other  
material to protect  
surface of door.  
2 x 6  
Place Door into Frame  
Hinge  
Lay frame on flat surface  
with hinges on jamb pointed  
up as shown.  
Slide door down on top  
of skids.  
Skid (2)  
Door Frame  
Door  
Skid  
Hinge  
4-9/16" Jambs  
Jamb  
Skid  
Door  
Hinge  
6-9/16" Jambs  
Jamb  
11  
 
DOOR INSTALLATION - continued  
9
Engage Hinge Knuckles  
Tap with hammer or rubber mallet as  
required to line up hinge knuckles and  
engage.  
Install Hinge Pins  
Hinge Pin  
Door  
Tap in pins. Be certain  
to insert pins so heads  
are on top edges of  
hinges.  
Door Frame  
Adjustable Hinge Option  
Fasten door panel  
to frame  
Prop up hinge side of  
door panel until hinges  
can align into mortises  
on hinge jamb.  
Fasten door panel to  
frame with #8 x 3/4”  
flat head screws,  
(2) in top hinge and  
(3) in middle and  
bottom hinge.  
#8 x 3/4”  
flat head  
screws  
Prop up  
#8 x 3/4”  
12  
 
ATTACH TRANSPORT CLIP  
10  
Standard Lock Option  
Transport Clip  
Attach Transport Clip to Door  
Insert tab into latch bore.  
Exterior  
side  
Position reference lip at edge of  
stile against exterior side of door.  
Fasten with (2) #6 x 3/4” flat head  
screws.  
#6 x 3/4"  
flat head  
screws  
#6 x 3/4”  
Attach Transport Clip to  
Frame  
Transport Clip  
Close door into frame ensuring  
margins are even at head jamb.  
Fasten transport clip to frame  
with (2) #6 X 3/4” flat head  
screws.  
#6 x 3/4"  
flat head  
screws  
Multi-point Lock Option  
Flatten lock tab with hammer.  
Flatten with  
hammer  
13  
 
ATTACH TRANSPORT CLIP - continued  
10  
Attach Transport Clip to Door  
Place flattened transport clip on top of  
door approximately 1 to 2 inches from  
lock side edge.  
#6 x 3/4"  
flat head  
screws  
Fasten with (2) #6 x 3/4” flat head screws.  
Attach Transport Clip to  
Frame  
Close door into frame ensuring  
margins are even at head jamb.  
Fasten transport clip to frame  
with (2) #6 x 3/4” flat head  
screws.  
#6 x 3/4"  
flat head screws  
UNIT READY FOR INSTALLATION  
11  
Unit can now be transferred for installation. Gather any remaining  
components and hardware as they may be used for installation.  
See “Unit Installation” instructions.  
14  
 
DOOR  
PATIO  
SYSTEMS  
1687 Woodlands Dr. Maumee, OH 43537  
1-800-THERMATRU (843-7628)  
© 2004 Therma-Tru Corp.  
Therma-Tru Doors is an operating company of Fortune Brands, Inc.  
03-01-04  
Part # AIHPSNGL  
 

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