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16
OVERLAY DOOR PANEL INSTALLATION
Table B
Material
Type #10 Wood Screw
Hardwood
1
⁄8" (3.2 mm) Diameter. Pilot Hole
Softwood
7
⁄64 (2.8 mm) Diameter. Pilot Hole
Step 4: Assemble the panel to the
door
The preferred method of attaching the panel to the
door is to clamp the panel to the door so it cannot
move while drilling the screw pilot holes. Use bar
clamps or "C" clamps with pads on the clamping
surfaces that will not mar the panel or the door.
The custom overlay panel should be ush with the
top of the door and centered along the width of the
door. See Figure 13a. Drill holes through the gasket
extrusion using the 10 holes as pilot holes. Use the
drill size from the chart in Table "B", being careful
not to drill through the front surface of the panel. If
the overlay panel is thinner than
5
⁄8" (16 mm) thick
shorter screws will have to be obtained. Fasten
the panel to the door with the 10 screws provided
in the literature pack. (See Figure 18a). Remove
the clamps and replace the gasket in the gasket
extrusion channels of the door. Some force may be
required to seat the gasket into the channels. Be
sure the gasket corners are seated properly.
Figure 18
3
1
⁄2"
(89 mm)
Counter bore lock
hole on back side.
Figure 18a
#10 x
1
⁄2"
screw
1
⁄2" (13 mm) diameter drill
through door panel, from
other side (see detail above)
13
⁄16" (20.5 mm) counter bore,
7
⁄16" (11 mm) deep.
17
⁄32"
(13.7 mm)
Hinge side of door
Step 5: Assemble lock parts
Two (2) lock extensions are provided with the lock.
Use the longer extension for
3
⁄4" thick overlay pan-
els and the shorter one for
5
⁄8" thick overlay panels.
Assemble the lock extension, cam stop washer,
spring washer, and set screw to the lock as shown
in Figure 19 and 20.
Install this lock assembly into the lock hole in the
overlay panel and secure with the retaining nut on
the back side with a 15 mm socket and ratchet.
Make sure the key slot in the front of the lock is
vertical.
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