Forest Xtend 4.0, Manual Book

Page 1: ...tion www forestgarden co uk Forest Garden Oak Drive Hartlebury Trading Estate Hartlebury Worcestershire DY10 4JB Thank you for purchasing your Xtend Garden Building from Forest Garden Simply follow these step by step instructions and our top tips for a straightforward assembly If you have any questions or need advice our friendly team is here to help ISSUE 0121 FIXING PACK CODE XTENDFP ...

Page 2: ...anslucent Silicone QTY 1 1 6mm Glazing Packers QTY 10 of Each 1 6 x 30mm Panel Pins QTY 155 300ml Anthracite Grey Silicone 7016 QTY 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 12mm Wood Plugs QTY 100 14 10 11 12 13 14 Drill 2 6 5mm Drill Bits Tools Required Assembly is relatively straightforward if your follow these step by step instructions We recommend getting everything aligned properly bef...

Page 3: ...ding Foam is just like many other types of expanding foam It is vital that you know how to set up and use the expanding foam correctly for an easy application during your assembly As this is a generic fixing pack and we do not supply any tools the expanding foam does require a foam gun Preparation Application Before applying your expanding foam you need to ensure that the surfaces to be bonded mus...

Page 4: ...e some general carpentry If you have any doubts as to your ability you should contact Forest Garden and arrange a professional team to assemble the building for you You should also pay special attention to the possibility of surrounding raised ground draining onto the slab or under your garden room Building the base correctly is very important cutting corners on this part of the project will poten...

Page 5: ...oles along the edge of the first floor panel Do not screw in the other side at the moment Using 125mm screws screw through the floor panel into the floor bearer beneath Repeat the process for the 4 other screws Ensure each screw is countersunk Place the second floor panel E onto the middle bearers Ensure the panel is positioned half way on both bearers Place the first floor panel D on top of the t...

Page 6: ... between the second and third panels Once happy that all panels are in the correct positions further secure with 5 x 125mm screws along the third panel edges and the first panels outer edge into the bearers beneath Screw positions are shown in the diagram above The larger screw heads are 125mm and the smaller ones are 35mm The final floor result should now be fully secured and flush around all fac...

Page 7: ...across the top and 5 down the sides of each OSB sheet Screw along the edges first 15 15 Insert and knock the floor capping AN into place using a rubber mallet Ensure it is flush to all edges 12 12 Apply OSB floor sheets AD AE on top of the SIPS panels one at a time Ensure they are flush to all edges and screw into the corners to keep secure 14 14 Some pieces may be oversized If this is the case sa...

Page 8: ...e into place 21 21 23 23 19 19 20 20 Using a Stanley knife cut the DPC at the corner to create 2 pieces to easily fold onto the OSB sheets and staple into place Continue folding the overhang and corners of DPC onto the OSB sheets as you make your way around and staple in place The final result is shown above Continue to wrap around the base We suggest one person unwraps and the other will follow b...

Page 9: ... from your door opening 29 29 Starting with the back floor plate AP ensure it s flush end to end and provide 11mm spacing from the bases back edge Pre drill and screw 4 x 125mm screws along the timber 26 26 Pre drill and use 4 x 125mm screws for the front floor plate AP Apply 2 x 125mm screws per end Measure out your front panel P and ensure your front panel is placed flush to the edge 28 28 The f...

Page 10: ...nto the floor plate and the wall panel will sit flush to the edge 35 35 Next start to build your walls Each wall panel is labelled accordingly to the layout shown above and the components list at the back of this guide 33 33 In the left hand corner the wall panel will be flush to the edge and the floor plate as shown above 36 36 Begin the build at the left back corner starting with Side Panel 4 J ...

Page 11: ...side with side panel 2 k 43 43 Repeat the same process on the last back panel L and knock into place 41 41 Pre drill and using the star drill bit provided in your fixing box screw through the back into the side wall panel using 3 x 150mm screws top middle and bottom 38 38 Add expanding foam into the inner side groove and into the bottom groove of the second back panel K Slide on the floor plate an...

Page 12: ...to the window insert batten behind Secure into place using 4 x 35mm screws internally and externally 2 x 35mm screws each side of the window insert 49 49 Apply the front wall panel P and butt up against the front side wall panel just secured Ensure all edges are flush 46 46 Knock the window insert AA into the section provided Ensure the top is flush 48 48 Apply the other front wall panel P Pre dri...

Page 13: ...rnally position the screws each side of the adjoining split line Use 5 x 35mm screws for each side of adjoining panels with the spline panel inside from top to bottom Repeat this process for every adjoining panel Use the expanding foam into the top groove ready for the wall plates Start at the front Position the screws on the Lintels OSB and screw into the wall batten behind Secure into place usin...

Page 14: ... the thicker section 65 65 Insert the side wall plate AN Pre drill and secure with 4 x 125mm screws Repeat the process for the other side wall plate and back wall plate with expanding foam and 125mm screws 62 62 Pre drill and secure with 4 x 125mm screws Repeat the same process for the back wall plate AP 60 60 Apply expanding foam to the side panels groove 61 61 Use 2 x 35mm screws to secure the c...

Page 15: ...for the third roof panel Y 73 73 Lift and position the second roof panel Y 70 70 Position the back of the roof panel Using the spirit level as a guide the top OSB sheet on the roof panel needs to be flush to the back edge Use 4 x 150mm screws along the edge 68 68 Use the spirit guide as a reference to screw through the roof panel into the side wall beneath Top Tip Use the canopy T G panel BD as a ...

Page 16: ...ffect the rest of the build 78 78 Pre drill and screw 5 x 35mm screws where the adjoining panels intersect 76 76 Repeat the same process as the first roof panel using 4 x 150mm screws along the edge to fully secure the roof Then secure the third roof panels opposite corners with 2 x 150mm screws 77 77 Use 4 x 80mm screws into the panel cap Use 3 x 35mm screws in between the 80mm screws to fully se...

Page 17: ...he door and window gaps 89 89 Continue unwrapping the membrane pulling tightly and stapling into place 86 86 Starting with the bottom section pull the membrane tightly and staple into place 84 84 Then warp the excess around the corner and staple the starting point into place 85 85 There will be a slight gap at the front and on the sides due to the angle of the roof 90 90 Repeat the same process fo...

Page 18: ... 95 95 Remove the roof overhang excess 97 97 Staple into place and remove the excess from the door section 94 94 Repeat the same process to remove the excess from the window section 92 92 Using the excess membrane cover the front flush up to the roof 93 93 The final result is shown above You do not need to add membrane to the canopy the roof overhang 98 98 Fold onto the roof stapling into place 96...

Page 19: ... knock the second back panel into the first so the T G interlocks the panels together Use a rubber mallet for a softer application Repeat the same process for the AX T G panel 101 101 Use 6 x 80mm screws on each panel 3 x 80mm down each side of the cladded panel through the batten and into the wall panel behind Leave the screws slightly out in case of adjustment 102 102 At each side there will be ...

Page 20: ... application Repeat the same process for the BA T G panel 106 106 Use 6 x 80mm screws per panel Ensure you use 3 x 80mm screws down each side of the cladded panel 104 104 Ensure the cladded panels are 45mm off the ground If you are using the batten as a guide slightly lift up the secured panel to ensure it is carefully removed to prevent any damage 105 105 Ensure the opening of the cladding is flu...

Page 21: ...peat this process for the other side 117 117 Apply the lintel panel BG This will fit in between the front panels Use 6 x 80mm screws Make sure to drill through the battens beneath 114 114 Use 3 x 80mm screws for the other edge of the side panel BC and screw into the front panel BE batten to secure together 112 112 Repeat the process for the other front panel BE 113 113 Position the front fascia En...

Page 22: ...much as possible 125 125 Apply glue to half of the roof and ensure to reach up to all of the edges 122 122 Fold the EPDM back to half way across the roof we recommend two people for this Be careful when moving on and around the roof to prevent any possible injuries 120 120 Pour the glue into a paint tray and use a roller for easier application 121 121 Finish with a final brush on the EPDM to produ...

Page 23: ...BA BH Screw into place using 2 x 80mm screws Repeat the process on the opposite side 130 130 Before adding the plastic roof trims on the sides the angled roof battens need to be applied to the gaps above the T G panels Fold the edge of the EPDM and slot in the batten onto the T G side panel BB 128 128 Screw into place using 2 x 80mm screws Ensure the batten is butted up to the T G panel and wall p...

Page 24: ...Stanley knife to score an outline to weaken the support 138 138 Use the clips provided to clip the pieces together Repeat the same process on the opposite side 136 136 Measure and cut the plastic trims into 2 equal pieces Ensure each end meets the side trims Pin these into place Add the clip in the centre of the adjoining trims 137 137 Once the plastic trims are complete around the roof using a St...

Page 25: ...ntain the 5mm expansion gap Ensure the back of the frame is in line with the OSB sheet inner face as shown above 147 147 Be sure to seal the ends of sill with the caps provided to prevent moisture from tracking along into the wood work 145 145 Apply adhesive silicone on to the base and carefully position the new frame into the aperture Ensure to centralise it 146 146 These should be drilled 150mm ...

Page 26: ...cone in the door section Be sure to seal the ends of sill and frame assembly to prevent moisture from tracking along the sill and into the wood work 158 158 As the pane is positioned the beading can be installed using a smaller rubber mallet and tapped securely back into place Be careful to not aim at the glass pane 155 155 Apply packers with the adhesive silicone The glass should be packed at dia...

Page 27: ...dow with 1 x 112mm screw into the top and 1 x 112mm into the bottom 166 166 This section is only for the Xtend Plus doors and side window This step will not apply to the standard option Use 3 x 35mm screws to secure the metal capping 163 163 Check that frame is both level and plumb then drill fixing holes into the frame side 161 161 These should be drilled 150mm from the top and bottom corners and...

Page 28: ...the door frame to hide the screws 172 172 The glass should be packed using the toe and heel process Toe and heeling works by supporting the double glazed unit with the packers 174 174 Repeat the same process centrally Screw 1 x 112mm screw in the centre 171 171 Then screw 1 x 112mm screw into the centre 169 169 Repeat the process through the top Drill 150mm from the both internal sides of the doub...

Page 29: ... back after twelve hours and will be fully cured in 12 24 hours 182 182 Repeat the same process for the internal strip 179 179 Repeat the same process for the other door and window panes ensuring it is centralised and packed properly with the toe and heel process Then add the window handle inside 177 177 For the adjoining frames attach the strip provided with the metal capping This will clip into ...

Page 30: ...sink the screws and enlarge the hole by 10mm 188 188 190 190 Secure into place with 5 x 30mm nails Repeat the process for the opposite side of the door frame Then repeat the same application around the window frame 187 187 Then cut to the desired size 185 185 Using 6 x 30mm nails secure the top board into the lintel Repeat the same process for trimming the sides 186 186 In your fixing box there wi...

Page 31: ... front down the side strip Repeat the same process for the opposite side 195 195 Pre drill across the top and repeat the same process Use 5 x pins across the front of the plastic trim 193 193 The side plastic trims for the door and window sizes will need to be trimmed down further to fit Mark out your required length and cut 194 194 Pre drill and use 5 x pins on the front of the side plastic trim ...

Page 32: ...lace 204 204 206 206 Repeat the same process to measure and mark out the position for the final back batten 203 203 Measure and mark out even spaces to position the two middle battens 201 201 Use 5 x 80mm screws to secure equally across the batten in place 202 202 Apply one batten above the door opening flush to the edge opening Apply the top batten flush to the top Use 5 x 80mm screws per batten ...

Page 33: ...dow and back These will be flush end to end and ensure they are the same height as the positioned back panels 211 211 Use 5 x 80mm screws for each batten The battens on the left hand side will not be aligned to the front batten positions 209 209 Repeat the same process for the two top battens and frame the window Apply the 45x28x1960mm battens one on either side using 4 x 80mm for each 210 210 Sta...

Page 34: ...om front to back If unsure use the below steps as a guide 220 220 222 222 Apply the 45x45mm roof battens Start at the front Ensure it is flush end to end and against the front beaded panels Secure with 5 x 80mm screws Repeat the same process at the back 219 219 Use 10 x 50mm screws for the window panel and the trimmed side panel Repeat the same process on the opposite side Both of these will be th...

Page 35: ...nt Work from left to right and ensure they line up with the secured roof panels Secure with 6 x 50mm screws per panel 227 227 Repeat the same process Ensure the rounded edge is butted up against the chamfered edge on the first panel Use 4 x 50mm screws on each side and 2 x 50mm screws in the centre for both panels 225 225 Apply the other trimmed beaded panel Use 8 x 50mm screws to secure 226 226 S...

Page 36: ...2 232 Apply the side framing using 5 x 30mm nails per board 236 236 238 238 Repeat the same process for the window framing Use 4 x 30mm nails to secure 235 235 The top frame will sit on top of the side boards Ensure both ends are flush to the side framing edge Trim if necessary 233 233 Fix into place using 6 x 30mm nails 234 234 Apply the overlapping framing Ensure flush around all edges and trim ...

Page 37: ... silicone consistent as you trail down 244 244 246 246 You will be provided a silicone seal for the windows and doors The colour provided will match your windows and doors 243 243 Use 5 x 30mm nails for the roof trims on each side The final result from the back 241 241 The above picture shows the final result of the windows and door 242 242 Repeat the same process on the opposite side 245 245 Fini...

Page 38: ...s doesn t harm the timber in any way but it does look unsightly A good quality exterior timber finish must be applied to the exterior of your garden room which offers protection from the extremes of our climate throughout the UK The 2 most common types of high quality exterior wood finish are penetrating finish and film finish Your Xtend garden building comes in an untreated form except for the be...

Page 39: ...t crack or peel and is easy to apply and maintain A suitable exterior timber finish must be applied to the exterior of your Xtend garden building in order to validate your guarantee Always read and follow manufacturer s usage and application guidelines We recommend the following exterior finishes Sikkens Cetol HLS Plus Restol Wood Oil Timmersol ETS Double Protectant Osmo Country Colour Osmo Natura...

Page 40: ...ine your subfloor with plywood for a wooden subfloor or use a self levelling compound for a concrete subfloor Install your wooden flooring in the correct position using any floor instructions you have been provided When you are fitting any type of wooden flooring you must leave an expansion gap at least 10mm around the edge of the room Floor Trim The type and size of floor trim around the floor is...

Page 41: ...T EPDM Rubber Roofing Glue Plastic Roof Trims 1 45452000PPT Back Roof Batten 45x45x2000mm Guttering 2 44411250RFP Side Back Angled Roof Batten 44x41x1250mm 2 44180530RFP Side Middle Angled Roof Batten 44x18x530mm 2 44431253RFP Side Front Angled Roof Batten 44x43x1253mm 2 50122410P Strip Door Framing 50x12x2010mm 1 50120605P Strip Window Framing 50x12x605mm 1 50121948P Strip Door Window Framing 50x...