7
Attach the Overlay Panel to the Sheet-metal Panel
1. Place the overlay panel face down on a soft, clean surface.
2. Secure the front of the sheet-metal panel to the back of the
overlay panel with masking tape.
3. Drill seven
⁵⁄₃₂
" x
³⁄₈
" (3.97mm x 9.53 mm) deep holes through
both panels as shown.
IMPORTANT:
■
Do not drill deeper than
³⁄₈
" (9.53 mm).
■
For the door to operate correctly, properly align the sheet-
metal panel and overlay panel.
4. Remove the tape from the overlay panel assembly.
5. Separate the overlay panel from the sheet-metal panel. Set
the overlay panel aside for later use.
6. Using a #7 drill bit, enlarge the seven holes in the sheet-metal
panel by drilling through the sheet-metal panel.
7. Place nylon spacers between the sheet-metal panel and
overlay panel.
8. Using eight #10 x
⁵⁄₈
" round-head screws, attach the overlay
panel to the sheet-metal panel as shown.
9. Remove the existing bottom pivot plate and discard. Install
the new bottom pivot plate.
NOTE: When installing the bottom pivot plate, be sure that
the flush side is facing out and the three holes are toward the
outside front of the door as shown.
Assemble the Door
1. Slide the overlay panel assembly into the door frame.
2. Slide the cardboard spacer between the overlay panel
assembly and the door frame.
NOTE: The cardboard spacer provides a tighter fit between
the overlay panel assembly and the door frame.
A. Side of overlay panel
B. Back of overlay panel
C. Masking tape
D. Sheet-metal panel
E. Bottom of overlay panel
A. Drilled holes
A
B
C
D
E
³⁄₈
"
(9.53 mm)
⁵⁄₁₆
"
(7.94 mm)
A
27" ±
¹⁄₄
"
(68.58 cm ±
6.35 mm)
1" ±
¹⁄₈
"
(2.54 cm ± 3.18 mm)
1" ±
¹⁄₃₂
"
(2.54 cm ± .79 mm)
14
⁵⁄₁₆
" ±
¹⁄₄
"
(36.35 cm ±
6.35 mm)
1" ±
¹⁄₃₂
"
(2.54 cm ± .79 mm)
11
⁷⁄₈
"
(30.16 cm)
A. Overlay panel
B. Pivot plate
C. Nylon spacer
D. Sheet-metal panel
E. #10 x
⁵⁄₈
" round-head screw
A. Door
B. Existing bottom pivot plate
C. Bottom pivot plate
D. #8—32 x
³⁄₈
" Hex sems screw
A
B
E
C
D
A
B
C
D
