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EXTERNAL DOOR & WINDOW FRAME & APPLYING WOOD PLUGS

Remove all excess expanding foam around the

window and door frames. Preferably, wait for the

expanding foam to cure for easier removal.

183

183

If any of the 50 x 12mm door and window boards

are slightly oversized, you will need to measure out

your required length. Start with the top board.

184

184

You will need to fill in the holes of each screw

in the T&G panels to create a flat finish. Further

countersink the screws and enlarge the hole’s 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

Cut the 50 x 12mm boards to the required 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

Insert the supplied wood plugs one at a time and

hammer further into the hole.

189

189

Finish with slightly cutting down and/or just

sanding off any excess showing to produce a

seamless finish. Repeat this process for every screw

hole in the T&G panels.

30

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Summary of Contents for Xtend 2.5

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 0221 FIXING PACK CODE XTENDFP ...

Page 2: ...oam QTY 3 Star Drill Bit QTY 1 310ml Translucent 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 you follow these step by step instructions All screw hole...

Page 3: ...ion B3 Fill Fix Expanding 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 surf...

Page 4: ...me general carpentry If you have any doubts as to your ability you should contact Forest Garden and arrange for a professional team to assemble the building for you Be aware of any raised ground surrounding the site of the garden room as this may cause water to drain onto the slab base or under the Xtend building Building the base correctly is very important cutting corners on this part of the pro...

Page 5: ... 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 A onto the middle and end bearers Ensure the panel is positioned half way on the middle bearer Place the first floor panel B on flush to the ...

Page 6: ...appy that all panels are in the correct position further secure with 5 x 125mm screws along the outer edge of the second panel Screw positions are shown in the diagram above The larger screw heads are 125mm and the smaller ones are 35mm The fully constructed floor should now be fully secured and flush to the edges of all the floor bearers Use a spirit level to ensure the floor is level before cont...

Page 7: ...ews screw 3 across the top and 5 down the sides of each OSB sheet Screw along the sides first 15 15 Insert and knock the floor capping AL into place using a rubber mallet Ensure it is flush to all edges 12 12 Position OSB floor sheets AG on top of the floor 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 i...

Page 8: ...o 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 into place The final result is shown above Continue to wrap around the base We suggest one person unwraps while the other follows behind...

Page 9: ... front floor plate starting from the end of the timber Repeat the process at the opposite end 29 29 Starting with the back Floor Plate AL ensure it is flush at each end and use the 11mm offcut to ensure an 11mm space from the base s back edge all the way along 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 AL Apply 2 x 125mm...

Page 10: ...all panel will sit flush to the edge 35 35 Next start to build your walls Each wall panel is labelled according 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 2 H Insert the expanding foam provi...

Page 11: ...nd bottom 43 43 Add expanding foam into the inner side groove and into the bottom groove of the second Back Panel H and knock into place to complete the back wall 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 Slide the Spline Q into the First Panel H Please note that Xtend2...

Page 12: ...wing from both outside and inside of each wall panel into the window insert This will use a total of 8 x 35mm screws 49 49 Install the Front Panel O and butt up against the front side wall panel installed in the previous step Ensure all edges are flush 46 46 Knock the Window Insert AA into the the space between Window Panel N and Window Panel N1 Ensure the top is flush 48 48 Install the other Fron...

Page 13: ...rews per panel once again Where spline panels have been used to join side panels use 5 x 35mm screws to secure from top to bottom along the connection Do not screw directly into the adjoining line Repeat this process for every adjoining panel Starting with the front panels apply expanding foam in the top groove ready to add the wall plates Use 35mm screws to secure the lintel in place by screwing ...

Page 14: ... thicker end of the firring component 65 65 Insert the Side Wall Plate AK Pre drill and secure with 4 x 125mm screws Repeat the process for the other side wall plate and the back wall plate 62 62 Pre drill and secure with 4 x 125mm screws Repeat the same process for the Back Wall Plate AL 60 60 Apply expanding foam to the groove of one of the side panels 61 61 Use 2 x 35mm screws to secure the thi...

Page 15: ...onsists of two roof panels This step does not apply to your build 70 70 Use the spirit level to ensure the top OSB sheet of the roof panel is flush with the back edge of the wall panel Top Tip Use the Canopy T G Panel BJ as a reference for the correct overhang size at the front 68 68 Use 4 x 150mm screws along the side edge 69 69 Lift up the second Roof Panel U and apply expanding foam into the in...

Page 16: ... the build 78 78 Pre drill and secure 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 second roof panel s other side edge with 2 x 150mm screws at each corner 77 77 Use 4 x 80mm screws into the front roof panel cap Use 3 x 35mm screws between the 80mm screws to ...

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 wrap 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: ...ve the excess from each side of the roof overhang 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 in...

Page 19: ...to softly knock the second back panel into the first so the T G Panels interlock 101 101 Use 6 x 80mm screws to secure each cladded panel 3 screws down each side Screw through the batten on the panel and into the wall behind Leave the screws slightly out in case of adjustment 102 102 At each side there will be a slight overhang of the T G board The batten s edge underneath attached to the panel sh...

Page 20: ... T G panels interlock 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 Install the Window Opening Panel BC ensuring it is flush to all edges If not ...

Page 21: ...he T G side panel Repeat this process for the other side 117 117 Install the Lintel T G Panel AW This will fit between the front panels Use 6 x 80mm screws Make sure to drill through the battens beneath 114 114 Use 3 x 80mm screws to secure the Window Opening Panel BC to the Front T G Panel AU 112 112 Repeat the process for the other Front T G Panel AU 113 113 Position the front fascia Ensure it i...

Page 22: ...ch all edges 125 125 Apply glue to half of the roof making sure to reach all 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 produce a flat and ev...

Page 23: ...or the other batten s on top of the other T G Side Panels BB BC Screw into place using 2 x 80mm screws Repeat the process on the opposite side 130 130 To install the Angled Roof Battens lift the EDPM and slot the matching batten s listed in the components list into place above each T G Side Panel BB BA 128 128 Screw into place using 2 x 80mm screws Ensure the batten is butted up to the T G panel a...

Page 24: ...rims when positioning the plastic trim on to the front fascia Pin into place 137 137 Once the plastic trims are complete around the roof using a Stanley knife remove all of the EPDM excess Use the plastic trims as a guide Be careful not to cut the T G panels behind 142 142 Hook and position onto the corner Pre drill to provide a hole for the pin 140 140 Simply break off the excess to produce the r...

Page 25: ...ls to level it and maintain 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 woodwork 145 145 Apply adhesive silicone to the base and carefully position the new frame into the aperture Ensure to centralise it 146 146 These should...

Page 26: ... 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 tapped securely back into place using a smaller rubber mallet Be careful to not aim at the glass pane 155 155 Insert packers with the adhesive silicone The glass should be packed at diagonally opposing corners to hold the casement square using the...

Page 27: ... 1 x 112mm screw into the top and 1 x 112mm into the bottom 166 166 Steps 163 164 178 and 179 are only for the Xtend Plus doors and side window These step will not apply to the standard option Use 3 x 35mm screws to secure the metal capping 163 163 Check the 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 corne...

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 for the top of the frame Drill 150mm from the both internal sides o...

Page 29: ...e cut back after 12 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 they is centralised and packed properly with the toe and heel process Then attach the window handle inside see Step 151 177 177 Where the frames adjoin clip the strip provided into the fixed metal cappin...

Page 30: ...ersink the screws and enlarge the hole s 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 Cut the 50 x 12mm boards to the required 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 Insert...

Page 31: ...he side strip for the door frame Repeat the same process for the opposite side 195 195 Pre drill across the top and repeat the same process Use 5 pins across the front of the plastic trim 193 193 The side plastic trims for the door and window will need to be trimmed to fit Mark out your required length and cut 194 194 Pre drill and use 5 pins down the front and 3 pins in the internal face of the s...

Page 32: ...ure into place 204 204 206 206 Repeat the same process to measure and mark out the position for the fourth 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 third batten in place 202 202 Secure one batten above the door opening flush to the edge opening Secure the top batten flush to the ceiling Use 5 x ...

Page 33: ...e left hand side will not be aligned to the front batten positions 209 209 On the right hand wall secure a batten at the top of the wall in line with the top back wall batten using 5 x 80mm screws Secure a second batten along the wall so it is flush with the top of the window frame Finish framing the window by securing a 45x25x1960mm batten on either side of the window using 4 x 80mm screws for ea...

Page 34: ...third batten and secure with 5 x 80mm screws 220 220 222 222 Apply the 45x45mm first roof battens Start at the back Ensure it is flush end to end and against the back beaded panels Secure with 5 x 80mm screws Repeat the same process at the front with the second batten 219 219 Use 10 x 50mm screws for the window panel and the trimmed side panel Repeat the same process on the opposite side except th...

Page 35: ...t is shown above 228 228 230 230 This step does not apply to Xtend2 5 You only have two beaded roof panels 227 227 Repeat the same process Ensure the rounded edge is butted up against the chamfered edge on the first panel 225 225 Use 4 x 50mm screws on each side and 2 x 50mm screws in the centre of the panel 226 226 Start to apply the internal framing for the door This is the same process as the e...

Page 36: ...de 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 the top framing 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 Install the 45mm overlapping framing on top of the beaded panel Ensure ...

Page 37: ...he amount of 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 at the back 241 241 The final result of the windows and door 242 242 Repeat the same process on the opposite side 245 245 Finish with traili...

Page 38: ...s of timber causing it to turn grey This doesn t harm the timber in any way but it does look unsightly Therefore a good quality exterior timber treatment must be applied the exterior of the garden room to protect it from the extremes of our climate Your Xtend garden building comes untreated the bearers are wrapped in DPC as they come in direct contact with the ground therefore the correct treatmen...

Page 39: ... scraper Recently a third finish has entered the market and is increasing in popularity This is a penetrating film finish hybrid It offers all the advantages of both types of finish and provides superior timber protection It doesn 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 yo...

Page 40: ... subfloor is flat and level If it is not you will need to either line your subfloor with plywood for a wooden subfloor or use a self levelling compound for a concrete subfloor Install your wooden flooring using any floor instructions you have been provided When 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...

Page 41: ...170x44x2528mm 1 25FASCIA343 Angled Fascias 170x44x343mm 2 SIPS25ROOFKIT EPDM Rubber Roofing Glue Plastic Roof Trims 1 45451260PPT Back Roof Batten 45x45x1260mm Guttering 2 44441252RFP Side Front Angled Roof Batten 44x44x1252mm Above T G Panel BA BC 2 50441250RFP Side Back Angled Roof Batten 50x44x1250mm Above T G Panel BB 2 50121570P Strip Door Framing 50x12x1570mm 1 50120605P Strip Window Framing...

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