Doorlite Installation Instructions
Basic Instructions(Don’t bore me with the details, I know what I’m doing)1. Place the frames on your door and trace around them. 2. Cut the marked rectangles out of your door. 3. Assemble the frames and glass in the holes in the door. |
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Detailed Instructions(What have I gotten myself into?)1. Get all the tools and materials you will need. a. 1-3/4" thick exterior door. b. pencil c. carpenter’s square d. drill e. 3/8" bit f. jig saw (hint: the Bosch 1587AVSK is a sweet machine) g. appropriate jig saw blade for your door (wood, metal, fiberglass) make sure it is long enough to go through the door for the full stroke. (4-1/2" or 5") see fig. 2 h. Phillips screwdriver i. helper (it take two people to lift a door) j wood glue k. optional flush cut detail saw (for cutting dowels fig. 6) l. sand paper (120 grit) m. 2 saw horses and a large work table. |
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| 2. Unpack your door lites and separate the frames from the glass. Make sure everything in the packing list (fig. 1) is there and is in good condition. |
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| 3. Mark cut lines on your door (see Layout Directions). | ||
| 4. Use the 3/8" drill bit to drill 2 holes inside each cut line. The hole should be big enough for your jigsaw blade. fig. 3 |
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| 5. Put the door on saw horses and use the Jigsaw to cut along the cut lines. For best results, keep the outside edge of the blade right on the pencil line. fig. 4 (You can widen the hole if it’s too small, but you can’t make it smaller if it’s too big.) Check the hole size by putting the frames in. Check both sides of the door. |
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| 6. Lay the door exterior side down on a work table, and dry fit the frames and glass in the holes in the door with the screws on the interior side. Use the pre-drilled holes in the interior frames to pre-drill the exterior frames. Make sure all glass is oriented the same direction. The wavy side of the glass should face the exterior side. Add a small amount of silicone on the outside edge where the glass touches the frame before final assembly. |
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| 7. Cover Screw Holes with Dowels. Push the dowel into the hole and draw a line for cutting. fig 5 (A flush cut saw can save a step and cut this in place fig. 6) Cut the dowel and insert with a little wood glue. Sand flush. |
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| Common sense disclamer: Crestview Doors is not responsible if you break your door or your body. Please be careful with both. Read the safety instructions that come with your tools. | ||