©2012 Pella Corporation
Part Number: 81CP0101
INSTALLATION INSTRUCTIONS - INSTRUCCIONES PARA
LA INSTALACIÓN
CLAD WINDOWS WITH FLUSH FLANGE
Lea las instrucciones en español en el reverso
Installation Instructions for Replacement of Aluminum Windows in Hard Coat Stucco
Applications in arid climates.
These instructions are designed for typical California hard coat stucco exterior applications. The
installation must leave the existing aluminum window frame and weep system in place. These
instructions are not to be used with any other construction method and rely on the integrity
of the existing aluminum window frame and flashing system. Building designs, construction
methods, building materials, and site conditions unique to your project may require an installation
method different from these instructions and additional care. Determining the appropriate
installation method is the responsibility of you, your architect, or construction professional. If you
have questions, please contact your local Pella retailer.
REMEMBER TO USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT.
Existing Aluminum
Window Frame
Flush Flange
Always read the Pella® Limited Warranty before purchasing or installing
Pella products. By installing this product, you are acknowledging that this
Limited Warranty is part of the terms of the sale. Failure to comply with all Pella installation
and maintenance instructions may void your Pella product warranty. See Limited Warranty for
complete details at http://warranty.pella.com.
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1
OPENING PREPARATION
D. Use pliers to remove the 2” section(s) of frame.
1D
E. Starting in the 2” frame notch, use a
reciprocating saw to cut the frame legs flush
with the drywall. Do not cut through the frame
exposing the rough opening. Do not damage
the drywall where it will remain exposed after
the new window is in place.
1E
Note: At the sill, ensure that 1/4” minimum
height of frame leg remains to act as a sill dam.
1/4" minimum
Repeat steps C - E for all four sides of the opening.
F. Remove any debris, paint or stucco from the
exterior face of the existing window frame that will
interfere with the new window installation. Clean any
dirt or debris from the existing sill and ensure the
weep holes are open and clear.
1F
G. Seal the existing jamb frame joints to the
sill of the existing aluminum window frame
with beads of sealant.
1G
H. Seal any screw holes from the original
divider with sealant. DO NOT plug any weep
holes in the existing frame.
Sealant
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1
OPENING PREPARATION
Window Frame Depth minus 1/4"
I. Install wood blocking around the entire opening.
The blocking must be the same height as the
existing aluminum window frame. The blocking must
extend to the interior far enough to provide full
support for the sill of the new window, however may
extend as far to the interior as desired. Set blocking
in sealant against drywall return to prevent air
infiltration.
Flashing Tape
Wood Blocking
1J
J. Apply sill flashing tape. Cut a piece of flashing tape
6" longer than the existing aluminum frame width.
Apply the tape bottom over the wood blocking so
it overhangs 1” into the first sill cavity of the existing
aluminum frame and goes up 3" each jamb.
K. Cut treated wood or PVC filler to loosely fit the
sill cavities in the existing aluminum frame. This
filler material will help support the weight of the new
window, but should not prevent water drainage. The
depth of the filler should be the same height as the
tallest leg of the aluminum frame. Cut the sill filler
to fill the entire length of the sill in both cavities. Cut
notches in the sill filler to correspond with the weep
holes of the existing aluminum window frame.
L. Install the wood filler into the existing aluminum
frame. Insert the sill filler with the notches over the
existing window weep holes. DO NOT block any
weep holes in the existing window.
Window Frame Depth minus 1/4"
Flashing Tape
Wood Filler
Wood Blocking
1L
1L
M. Install and level sill spacers. Place 1" wide x 1/4-3/8"
thick spacers on the bottom of the window opening
1/2" from each side and 1/2" back from the interior
surface of where the new window will rest. Spacers
are also required below mullions and at screw anchor
locations.
1M
Note: The depth of the shim should be equal to the
window frame depth minus 1/2". Cut the shim to this
dimension. Place the exterior edge of the shim flush
with the exterior of the existing window. Improper
placement of shims may result in bowing the bottom
of the window.
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2
WINDOW PREPARATION
A. Casement:
On the room side of the window drill 1/8" diameter clearance holes through the head,
jambs and sill of the frame. Space the holes a maximum of 6" from each end and a
maximum of 16" on center.
Note: On vent casements, place the holes so they do not interfere with the roto operator
and the latch points on the lock side of the window.
EVERY
6"
16"
6"
Drill 1/8"
clearance hole
6"
6"
EVERY
16"
EVERY
16"
Single
Window
2A
Casement Sill
6"
6"
B. Double-hung and Clad Frame:
On the room side of the window, drill 1/8" diameter clearance holes
through the frame at the locations shown. Space the holes a maximum
of 6" from each end and a maximum of 16" on center.
Note: The lower sash must be raised to drill the holes in the sill of the
double-hung window.
Designer Series®
and ProLine®
Architect Series®
Double-Hung
Double-Hung Head
Double-Hung Head
1/2"
Drill 1/8"
clearance hole
Drill 1/8"
clearance hole
2B
2B
Clad Frame Head
1"
Double-Hung Jamb
Double-Hung Jamb
Drill 1/8"
clearance hole
Drill 1/8"
clearance hole
2B
1/4"
Drill 1/8"
clearance hole
Drill 1/8"
clearance hole
2B
2B
1"
Drill 1/8"
clearance hole
Drill 1/8"
clearance hole
1/2"
Clad Frame Sill
Double-Hung Sill
Double-Hung Sill
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3
SETTING AND FASTENING THE WINDOW
A. Test fit the window in the opening from
the exterior. Insert shims around the
window temporarily while you verify that
the window will fit into the opening and
the window flanges will overlap the stucco
or existing aluminum window frame by a
minimum of 3/4" on all (4) sides.
Window
Frame
Note: Fix any problems with the opening
before proceeding. If required, the
exterior flush flange may be trimmed to
fit inside exterior surround trim. Lay the
window down on a flat surface. Use an
electric shears, circular saw or table saw to
cut the flange.
3/4"
Min.
3A
Pella SmartFlash Tape
B. Apply Pella SmartFlash tape across the
head of the window extending 6" down
each jamb. Place the tape starting on the
aluminum cladding and extending onto
the wood frame.
3B
6"
6"
6"
6"
Exterior
C. Place a 3/8" diameter (min.) line of sealant around
outside edge of the existing window frame where
the frame meets the stucco. It is important to leave
a 2" gap in the sealant line at each of the weep holes
of the existing aluminum window frame.
3C
Weep holes
TWO OR MORE PERSONS WILL BE REQUIRED FOR
THE FOLLOWING STEPS.
D
Insert the window from the exterior of the building
and center the window in the prepared opening.
E. Place a shim aligned with the top pre-drilled hole in
one jamb of the window frame. Trim all shims so they are
recessed back 1/4" - 1/2" from the interior face of the
window frame. Partially insert one 3-1/4" finish wood screw.
Repeat on the other jamb.
3E
F. Continue placing shims at each pre-drilled hole
as needed to plumb and square the window. Check
the window for square by making sure the diagonal
measurement from corner to corner of the replacement
window is within 1/8" in both directions. Insert a 3-1/4" finish
wood screw into each pre-drilled hole in the frame. Finish
inserting the top screw in each jamb.
Note: DO NOT shim above the window. DO NOT over shim.
MAKE SURE THE FLANGE REMAINS PRESSED FIRMLY AGAINST THE WALL SURFACE
WHILE PLACING SHIMS AND FRAME SCREWS
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4
APPLY ExTERIOR PERIMETER SEALANT
A. Place a corner bead of sealant on the edge
of the window flush flange on top, sides and
bottom to the stucco. Leave a 2" gap in the
sealant bead at the bottom, corresponding
to the weep hole locations in the existing
aluminum window frame.
Exterior
4A
2"
5
INTERIOR SEAL
CAUTION: Ensure use of low pressure polyurethane window and door insulating foams
and strictly follow the foam manufacturer’s recommendations for application. Use of
high pressure foams or improper application of the foam may cause the window frame
to bow and hinder operation.
A. Apply insulating foam sealant. From the interior,
insert the nozzle of the applicator approximately 1"
deep into the space between the window frame (not
jamb extension) and rough opening and apply a 1"
deep bead of foam. This will allow room for expansion
of the foam and will minimize squeeze-out. Apply
sealant across the interior surface of shims to create a
continuous seal. Follow manufacturer’s instructions.
5A
Note: It may be necessary to squeeze the end of the tube with pliers to be able to insert
into the space between the window frame and the rough opening. DO NOT completely
fill the space from the back of the flange to the interior face of the window
B. Check the window operation (vent units only) by opening and closing the window.
Note: If the window does not operate correctly, check to make sure it is still plumb, level,
square, and the jambs are not bowed. If adjustments are required, remove the foam with a
serrated knife. Adjust the shims and reapply the insulating foam sealant.
Interior Finish or Trim:
The space between the new window and the existing window’s frame will need to be covered
with trim. There are many ways to accomplish this and each case can be unique. How this is
done will be the decision of the homeowner or window installer. A few possibilities include
using cove, quarter round, or a stop moulding.
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ExTERIOR FINISH OF ALUMINUM CLAD WINDOWS
The exterior frame and sash are protected by aluminum cladding with our tough EnduraClad® or
EnduraClad Plus baked-on factory finish that requires no painting. Clean this surface with mild
soap and water. Stubborn strains and deposits may be removed with mineral spirits. DO NOT use
abrasives. DO NOT scrape or use tools that might damage the surface.
Use of inappropriate solvents, brickwash or cleaning chemicals will cause adverse reactions with
window and door materials and voids the Limited Warranty.
INTERIOR FINISH
If products cannot be finished immediately, cover with clear plastic to protect from dirt, damage
and moisture. Remove any construction residue before finishing. Sand all wood surfaces lightly
with 180 grit or finer sandpaper. DO NOT use steel wool. BE CAREFUL NOT TO SCRATCH THE
GLASS. Remove sanding dust.
Pella products must be finished per the below instructions; failure to follow these instructions voids
the Limited Warranty.
•
•
On casement and awnings, it is optional to paint, stain or finish the vertical and horizontal
sash edges.
On single-hungs and double-hungs, do not paint, stain or finish the vertical sash edges; any
finish on the vertical sash edges may cause the sash to stick. It is optional to paint, stain or
finish the horizontal sash edges.
•
On patio doors, it is optional to paint, stain or finish the vertical and horizontal panel edges.
Note: To maintain proper product performance do not paint, finish or remove the weather-
stripping, mohair dust pads, gaskets or vinyl parts. Air and water leakage will result if these
parts are removed. After finishing, allow venting windows and doors to dry completely before
closing them.
Pella Corporation is not responsible for interior paint and stain finish imperfections for any product
that is not factory-applied by Pella Corporation. Use of inappropriate finishes, solvents, brickwash,
or cleaning chemicals will cause adverse reactions with the window and door materials and voids
the Limited Warranty.
For additional information on finishing see Pella Owner’s Manual or go to www.pella.com.
CARE AND MAINTENANCE
Care and maintenance information is available by contacting your local Pella
retailer. This information is also available at www.pella.com.
IMPORTANT NOTICE
Because all construction must anticipate some water infiltration, it is important that the wall system
be designed and constructed to properly manage moisture. Pella Corporation is not responsible
for claims or damages caused by anticipated and unanticipated water infiltration; deficiencies in
building design, construction and maintenance; failure to install Pella® products in accordance with
Pella installation instructions; or the use of Pella products in wall systems which do not allow for
proper management of moisture within the wall systems. The determination of the suitability of all
building components, including the use of Pella products, as well as the design and installation of
flashing and sealing systems are the responsibility of the Buyer or User, the architect, contractor,
installer, or other construction professional and are not the responsibility of Pella.
Pella products should not be used in barrier wall systems which do not allow for proper
management of moisture within the wall systems, such as barrier Exterior Insulation and Finish
Systems, (EIFS) (also known as synthetic stucco) or other non-water managed systems. Except
in the states of California, New Mexico, Arizona, Nevada, Utah, and Colorado, Pella makes no
warranty of any kind and assumes no responsibility for Pella windows and doors installed
in barrier wall systems. In the states listed above, the installation of Pella products in barrier
wall or similar systems must be in accordance with Pella installation instructions.
Product modifications that are not approved by Pella Corporation will void the Limited Warranty.
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INSTALLING ROTO COVER AND CRANK
Note: Finish the interior of the window and allow the
window to dry before proceeding with these instructions.
(To open the window for finishing, partially insert the lock
handle into the jamb, unlock the unit, temporarily attach the
crank handle and turn to open.)
Pocket End
Screw Hole
A. Place the cover over the operator stud and snap into
Operator Stud
A
place. Position the pocket end of the cover into place.
Note: If the cover does not have the screw hole, apply
pressure on the pocket end of the cover to snap the cover
into place and proceed to step C.
B
B. Insert the provided screw into the hole in the bottom
of the pocket. Use a # 1 Phillips screwdriver to secure
the pocket screw snug against the bottom of the pocket
to avoid scratching the crank handle knob. DO NOT over
tighten.
C. Use a medium size flat-blade screwdriver to loosen the
Crank Handle
D
set screw in the crank handle.
Operator Stud
D. Slide the crank handle onto the stud. Unlock, open
window, then close and lock window.
E. Fold the crank handle down and check alignment of knob
Set Screw
with the pocket.
C
Note: You may need to adjust the crank position on the stud
until the correct alignment is achieved.
Knob
E
F. Open the crank and tighten the set screw.
G. After the final installation, fold the crank over and snap
the knob into the pocket.
Note: Even with the window open the crank can be folded
to avoid interferring with the window treatments.
Pocket
LOCK LEVER REMOVAL AND INSERTION
Note: You may want to remove the lock lever prior to finishing the window, or if it needs
to be replaced with a lock lever in a different finish.
A. Unlock and open the window.
B. Place the lock lever in the locked position.
C
Interior
Exterior
B
C. From the exterior of the window, insert a
small flat-blade screwdriver between the cam
and lock lever near the bottom of the opening
between the stop and frame gasket.
D. Push the screwdriver inwards with a small
amount of pressure; then turn the blade slightly
clockwise for a left hand unit, counter-clockwise
for a right hand units. DO NOT over-twist the
screwdriver, this can damage the lock driver.
Exterior
E
F
Interior
Note: This will release the hook in the lever
from the cam hook.
E. Remove the lock lever by pulling it toward the
interior of the building.
D
F. To install a lock lever, hold it in the lock
position and insert it, from the interior, into the
slot until it snaps into the cam.
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