16
!
CAUTION
OVERLAY DOOR PANEL INSTALLATION
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
flush 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 22a). 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.
Material Type
#10 Wood Screw
Hardwood
1
⁄
8
" (3.2 mm) Diameter. Pilot Hole
Softwood
7
⁄
64
(2.8 mm) Diameter. Pilot Hole
Table B
Weight of overlay door panel must not exceed 15
pounds (6.8 kg) for a solid door model or 10 pounds
(4.5 kg) for a glass door model.
Figure 22
3
1
⁄
2
"
(89 mm)
Counter bore
lock hole
on back side.
Figure 22a
#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
