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Ultimate Flip Lever

 Astragal Cut Down Instructions

STEP 1 (CONT.): INITIAL PREPARATION

d

. Rotate the bolt head out of the channel in the astragal and 

slide the bolt assembly out of the astragal.

f.

 Remove the upper trim cap, and tail cap if 

present, from the astragal body.

Ensure the upper bolt is in the unlocked position 
before removing. 

!

c

. Remove the orange securing pin from the upper bolt 

sleeve. Slide the bolt sleeve out of the astragal.

e

. Remove the U-clip from the astragal body 

and set aside.

Summary of Contents for Ultimate Flip Lever Astragal

Page 1: ...re Chop Saw Flathead Screwdriver Phillips Screwdriver Tools Required STEP 1 INITIAL PREPARATION c If present remove the trim strip from the astragal body Y X a Measure the length of the door panel X and the length of the astragal Y on the narrow edge b Round the length of the door panel X and the length of the astragal Y down to the closest inch Subtract the rounded length of the door panel from t...

Page 2: ...nd slide the bolt assembly out of the astragal f Remove the upper trim cap and tail cap if present from the astragal body Ensure the upper bolt is in the unlocked position before removing c Remove the orange securing pin from the upper bolt sleeve Slide the bolt sleeve out of the astragal e Remove the U clip from the astragal body and set aside ...

Page 3: ...vot Lower Flip Lever Lug Upper Flip Lever Lug Lower Drive Channel Notches a Disengage the spring from the spring bracket and spring pivot and set aside b Engage the flip lever into the locked position to access the center mounting screw c Remove the mounting screw and T nut from the center of the flip lever assembly and set it aside Center Mounting Screw ...

Page 4: ...ere the upper flip lever lug aligns with a notch in the upper drive channel Note The marked notch on the upper drive channel may not be the last notch e Make a mark on the astragal body where the lower flip lever lug aligns with the notch in the lower drive channel STEP 2 CONT REMOVE THE FLIP LEVER ASSEMBLY f Remove the lower flush bolt and the lower drive bar from the astragal body g Remove the u...

Page 5: ...agal and measuring along the wide side measure and mark X 9 16 Cut the astragal flush at this location IFYOU DO NOT HAVE ATAIL CAP AVAILABLE b To renotch the astragal measure 9 16 from the cut end of the astragal Usingachopsaw cutatthispoint untilthespacebetween the rows of holes in the astragal body Do not cut it flush 9 16 Cut Flush X a Starting at the bottom of the astragal and measuring along ...

Page 6: ...a new notch lines up with the marks previously made Example If your index number was 6 slide the upper drive channel down 2 notches because 6 4 2 New notch aligns with mark f Insert the flip lever assembly into the astragal body ensuring the flip lever lugs align with the marks made on the astragal body Ensure the flip lever assembly sits flush in the body with the lugs securely inserted in the no...

Page 7: ...ber of notches the upper drive channel was moved in Step f Once the location of the spring bracket is set reinstall the spring between the spring pivot and spring bracket Example If your index number was 6 move the spring bracket up 2 notches because 6 4 2 STEP 5 REINSTALLTHE BOLTS a Reinstall the upper trim cap onto the top of the astragal body b Slide the upper bolt assembly into the astragal bo...

Page 8: ...ecuring pin into the hole that aligns The bolt sleeve should never be more than 1 4 inset from the top of the astragal Neither row of holes align with astragal body Bolt may be up to 1 4 inset Holes align Body darkened for contrast Body darkened for contrast e Insert the orange securing pin through the bolt sleeve into the hole that aligns with the holes in the astragal body g Reinstall the U clip...

Page 9: ...ngaged positions Upper Bolt Lower Bolt a Reinsert the presized trim strip between the bottom bolt and the flip lever assembly Insert the longer piece of trim strip on the top part of the astragal ensuring it completely covers the upper bolt head Note the trim will not securely fit over the other components but do not cut it at this time Trim is hidden for clarity ...

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