© 2011 Pella Corporation
Part Number: 81CM0100
INSTALLATION INSTRUCTIONS - INSTRUCCIONES DE INSTALACION
ALUMINUM-CLAD SLIDING PATIO DOORS WITH
FLUSH FLANGE
Lea las instrucciones en español en el reverso
Installation Instructions for Replacement of Aluminum Sliding Doors in Hard Coat Stucco
Applications in arid climates.
These instructions are designed for typical hard coat stucco exterior applications in arid climates.
The installation must leave the existing aluminum door 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 sliding door 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.
Wood
Blocking
Flush
Flange
Existing Aluminum
Door Frame
Sill Pan
Optional Sill Nose
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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OPENING PREPARATION
2
A. Prepare the door opening by removing the venting
panel and the glass from the existing fixed side of the
aluminum door frame.
Note: It may be necessary to cut the divider
between the venting panel and fixed glass areas
with a reciprocating saw. The existing aluminum
frame is left in place so as not to disturb the existing
exterior stucco flashing or drainage system.
2A
2B
2B
B. Cut the existing door sill out of the opening. Using a
reciprocating saw or side grinder, cut the existing sill as
close to the longest leg of the jamb extrusion as possible.
Note: Be careful to avoid damage to the interior
flooring materials. Drilling holes in the sill prior
to cutting may make the removal of the existing
sill easier. If existing sill has a stainless steel cap
on the sill, removing the cap prior to cutting will
make cutting easier.
C. Clean old sealant and other debris from the
door opening.
2B NOTE
D. Remove the door lock strike from the lock
jamb of the existing door frame.
E. Place a bead of sealant at each joint where the
existing door frame jambs meet the existing
door sill pieces. Fill any holes in the jamb and
head with sealant.
2F
INTERIOR
F. If the weep holes of the existing sill have been
cut away, drill new weep holes in the existing
door jambs. Be sure to drill weep holes in all
vertical jamb legs, except the most interior leg.
2E
Note: Ensure all new or existing weep holes are
open before proceeding with the installation.
G. Cut wood blocking to fill the vent and fixed panel
cavities in the head and jamb of the existing door
frame. The depth of the blocking should be the
same height as the tallest leg of the existing jamb
extrusion. Cut the head blocking to fill the entire
length of the head in both channels. Cut the
jamb blocking to fill both jamb channels to within
approximately 1" of the bottom of the jamb.
2G
H. Set the wood blocking in sealant in the existing door frame. Make sure the blocking is
flush with the furthest protruding part of the existing jamb. Place a 3/16" bead of sealant
in the door panel cavities, then insert the wood blocking into the head cavities followed
by the jamb cavities. Next insert the wood blocking into the jamb panel cavities of the
existing door frame. Secure the blocking by pre-drilling and inserting #8 x 2-1/2" screws.
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OPENING PREPARATION (CONTINUED)
2
I. Construct a sill pan for the door. Measure the rough opening width and add 2". Measure
1" up from each end and cut through the vertical leg of the pan material. If there is a step
down at the exterior of the door opening, make the sill pan depth equal to the door frame
depth - 2-1/8". If there is NO step down, make the sill pan depth equal to the frame depth.
Bend the bottom (side) flaps of the pan material up, then bend the back leg around the
end of the pan.
Dry fit the sill pan and the door into the opening.
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J. If there is a step down at the exterior of the door opening, cut the sill nosing to the
rough opening width plus two times the flange width. Notch the sill nosing. If there is
NO step down, skip to step K.
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Note: If the new door frame is deeper than the existing door frame, it will be necessary
to cut the interior flooring material back to allow the door flush flanges to contact the
existing aluminum door frame.
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OPENING PREPARATION (CONTINUED)
2
K. Apply five lines of 3/8" diameter sealant across the rough opening sill in the
location shown. Make sure the lines of the sealant covers the area between the
stucco and rough opening.
Sealant lines and sill pan if there
is a step down.
Sealant lines and sill pan if there
is NO step down.
Flashing
Flashing
Tape #2
Tape #2
2O
Flashing
Tape #1
Flashing
Tape #1
Sill Pan
6"
6"
2M
2O
Sill Pan
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Five
Sealant Lines
2K
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Stucco
Sill Nosing
2N
L. Place a 3/8" bead of sealant at each corner of
the rough opening from the stucco along the
edge of the rough opening as shown.
Note: It is important to avoid letting the sealant
skin over prior to applying the sill pan.
2L
M. If using sill nosing with a step down, Install the
sill pan and sill nosing into the opening. Press down
to seal them into the opening. DO NOT overlap.
2N
2M
Sill Nose
Sill Pan
2N
N. Apply sealant at nosing ends continuing from the front of the sill pan
around the exterior surface of the wall where the sill nosing will end.
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OPENING PREPARATION (CONTINUED)
2
O. Cut two pieces of flashing
2O
tape 12" longer than the
rough opening width. Place
tape #1 across the sill nosing
just up to where the nosing
begins to slope down and
extending 6" up each jamb.
Apply the second piece of
flashing tape over-lapping
the first piece and the exterior
edge of the sill pan and 6" up
each jamb.
SILL TAPES
#2
Sill Pan
#1
2O
Sill Nose
PREPARE THE DOOR FOR INSTALLATION
3
TWO OR MORE PEOPLE WILL BE REQUIRED TO HANDLE THE PANEL AND FRAME SAFELY.
A. Remove the plastic wrap and cardboard packaging from the door.
Note: If screens, grilles or hardware are removed from the door at this time, label them
and store them in a protected area.
B. Remove the shipping spacers. Carefully slide the movable panel halfway open and
remove the spacers from both the top and bottom of the movable panel.
C. Remove the venting panel by lifting it off of the lower track and tilting the bottom of the
panel away from the door frame. Then, lower the panel out of the top track. Carefully set
the panel aside.
D. Drill 13/64" diameter clearance holes through the frame at a 45° angle, on the room side
of the door lock jamb and fixed jamb in the locations shown. Space the holes a maximum
of 6" from each end and a maximum of 10" on center.
EXTERIOR
3D
FIXED JAMB
VENT JAMB
6" MAX
Drill 13/64" clearance holes
through frame at 45° angle
10" MAX
10" MAX
10" MAX
10" MAX
INTERIOR
E. Drill a 13/64" clearance hole through the door
frame at each indentation in the extrusion at the
top (head) of the door frame.
10" MAX
10" MAX
10" MAX
6" MAX
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PREPARE THE DOOR FOR INSTALLATION (CONTINUED)
3
Pella
SmartFlash
Tape
F. Doors using Installation Clips: Install
installation clips. Place the clip so that the
lip is facing up and against the flush flange,
at the locations shown in the placement
diagram. Secure the clip by driving #6 x
5/8" corrosion resistant screws through the
outer two holes of the three holes shown.
#6 x 5/8” corrosion
resistant screws
3F
6“ from end
Lip
3G
6"
6"
Pella SmartFlash Tape
G. Apply Pella SmartFlash
tape across the head of
the door extending 6"
down each jamb. Place
the tape starting on
the aluminum cladding
and extending onto the
wood frame.
SETTING AND FASTENING THE DOOR
A. Dry fit the door into the opening.
4
Note: If the new door frame is deeper than the existing door frame, it will be
necessary to cut the interior flooring material back to allow the door flush flanges to
contact the existing aluminum door frame.
B. From the exterior, set the door into the opening. Set the sill of the door on the sill
panel and tilt the door into position.
C. Insert shims around the door temporarily while you verify that the door will fit into the
opening and that the door flanges will overlap the stucco or existing aluminum door
frame by a minimum of 1/2" on all sides.
REMOVE THE DOOR FROM THE OPENING
D. Place three 3/8" beads of sealant. Place the first beads sealant 1/2" in front of the base
of the interior sill pan lip. This bead should also continue up the corner of the sill pan
at each end, sealing the vertical joints of the sill pan and up 6" onto each jamb side of
the rough opening. The second bead should be approximately 1/2" from the exterior
edge of the frame wall, running from jamb to jamb with a 2" break in the middle of the
opening. Place a third sealant bead 1/4" from the exterior edge of the flat portion of the
sill nose or the sill pan. Start and stop this sealant line 1" from each jamb.
Application without
sill pan
1/2"
1st Bead
1st Bead
2nd Bead
2nd Bead
6
"
3rd Bead
6"
3rd Bead
Leave a 2"
break in
Leave a 2"
break in
center of pan
INTERIOR SILL P
center of pan
AN LIP
1
"
1
"
SILL NOSE
4D
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SETTING AND FASTENING THE DOOR (CONTINUED)
4
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E. Place a 3/8" diameter continuous bead of sealant on
the face of the existing door frame jambs and head.
TWO OR MORE PEOPLE ARE REQUIRED FOR
THE FOLLOWING STEPS
4E
F. From the exterior, set the door into the opening. Set
the sill of the door onto the sill pan and tilt the door into
position, centering it in the opening. DO NOT slide the
door on the sill pan.
G. Insert the door from the exterior of the building. DO
NOT slide the bottom of the door into the opening.
Sliding will damage the sealant lines. Place the bottom
of the door at the bottom of the opening, then tilt the
top into position. Center the door between the sides
of the opening to allow equal clearance for shimming.
Frame Screw Method: Insert one #8 x 3" screw into
the top anchor hole on each side of the frame.
Installation Clip Method: Insert one screw into one
hole in each of the top clips.
Exterior View
4F
H. Insert shims between the door and the sides of
the opening at the top two anchor hole locations in
the door. Keep shims back 1/2" from interior face
of the door frame.
Note: Keep the exterior of
the door pressed against the
Interior
existing door frame to ensure
a good sealant line.
4H
I. Plumb and square door. Insert
shims, as necessary, between
the door and the sides of the
rough opening starting up 6"
from the bottom of the door.
Keep shims back 1/2" from
4J
1
INCHES
0
m
2
0
2
3
3
4
0
interior face of the door frame.
5
0
6
0
7
0
Note: DO NOT OVER SHIM.
J. Check the interior reveal. Make sure the measurement from the interior face of the door
to the interior face of the wall is equal at several points around the door.
Note: If the dimensions are not equal, check to make sure the fins are folded out to 90°
at all points.
K. Secure the frame. Insert a 1" wide
shim behind the pilot hole at the lock
strike(s). Insert a #8 x 2-1/2" screw
4K
4K
(included in the panel retainer and
screw package) into the pilot hole
making sure it passes through the
shim and into the rough opening.
Shim
Shim
Note: The weather-strip must be
pushed aside to reveal the pilot
hole. Be careful not to damage the
weather-strip.
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SETTING AND FASTENING THE DOOR (CONTINUED)
4
Frame Screw Method:
Note: If using installation clips, proceed to step 4N.
4L
Interior
Fixed Panel
Threshold
4M
Exterior
L. Apply sealant and insert a #8 x 2-1/2" pan head (provided) or 3/16" x 1-3/4"
concrete screw into each hole in the bottom of the door frame, as indicated above.
M. Position and secure the panel retainers by drilling pilot holes through the remaining
holes in the retainer into the sill support or wood blocking, then apply sealant to the
holes and insert a screw into each hole as specified below.
Aluminum sill support: 9/64" pilot holes, #10 x 3/4" thread cutting screws (provided).
Wood blocking: 1/8" pilot holes, #10 x 2-1/2" flat head corrosion resistant wood
screws (provided).
Masonry floor: 3/16” x 1-3/4” concrete screws. Pilot drill per screw manufacturer’s
recommendations.
Installation Clip Method:
N. Fasten the door to the opening by driving two #8 x 1-1/4" corrosion resistant screws into
the pre-punched holes in the clips. If the clips are bent and fastened to the interior stud/
block, install the screws as close to the bend as possible.
Note: DO NOT shim above the door. For masonry openings use two 3/16" x 1-1/2"
masonry screws per clip. Pre-drill the masonry before attempting to drive the screws in.
4N
O. Drive #10 x 3-1/2" corrosion resistant wood screws through the holes in the
threshold in to the floor.
Note: For concrete floors, use masonry screws a minimum size of 3/16" x 3-1/2".
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INSTALLING THE INTERIOR INSTALLATION SCREWS
5
A. Drill 1/8" x 1" deep pilot holes into the rough framing through the clearance holes in
the top (head) and sides (jambs) of the unit frame.
B. On the sides of the door, drive #10 x 3-1/2" corrosion resistant wood screws through
the door frame into the rough framing. Drive the screws until snug, DO NOT over-
tighten the screws. DO NOT bend or bow the unit frame.
EXTERIOR
STUCCO
EXTERIOR
STUCCO
FIXED JAMB
VENT JAMB
INTERIOR
INTERIOR
R I O R
Drill 1/8" diameter pilot
hole through the clearance
hole in the frame.
5A
5B
#10 x 3-1/2"
corrosion resistant wood screw
13/16" Pilot
C. Apply sealant to each
pilot hole drilled in the
top (head) of the door
frame, then insert a #10 x
3-1/2" corrosion resistant
screw into each hole.
Sealant
goes here
5C
REINSTALL THE SLIDING PANEL
6
TWO OR MORE PEOPLE WILL BE REQUIRED TO HANDLE THE PANEL SAFELY.
A. Insert door panel. From the exterior of the building, tilt the
top of the panel toward the door frame and insert the top
of the door panel into the top track. Move the bottom of the
panel toward the door frame until it is vertical. Gently set the
panel down into the bottom track. Adjust the panel clip and
tighten the panel clip screw.
6A
Note: Be careful not to pinch your fingers between the
two panels. DO NOT close the sliding panel until you have
installed the hardware. The door may lock when closed.
B. Install the handles and panel retainer. Follow the instructions included in the hardware
package. If the panel is not square to the door frame, adjust the bottom rollers by
removing the adjusting hole cover and inserting an 8" long #2 Phillips screwdriver into
the hole. Turn clockwise to raise the panel and counter-clockwise to lower the panel.
C. Install screen. Instructions for installing the screen are found in the screen door package.
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APPLY EXTERIOR PERIMETER SEALANT
7
A. Place a corner bead of sealant on the edge of the door flush flange on top and
sides. DO NOT seal the sill of the door frame to the opening.
JAMB CROSS SECTION
Exterior View
7A
E R I O R
INTERIOR
7A
FIXED JAMB
EXTERIOR
STUCCO
Flush flange
8INTERIOR SEAL
Caution: Ensure use of low pressure polyurethane window and door installation 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 door to bow
and hinder operation.
A. Apply insulating foam. From the interior,
8A
insert the nozzle of the applicator
approximately 1" deep into the space
between the door and the 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. For doors with
jamb extensions installed, ensure the foam
is placed between the door frame and
the rough opening, not between the jamb
extension and the rough opening. Follow
foam manufacturer's instructions.
Interior
Note: It may be necessary to squeeze the
end of the tube with pliers to insert it into
the space between the door frame and the
rough opening. DO NOT completely fill the
space from the back of the brickmould to
the interior face of the opening.
8C
6"
B. Check the door operation by opening and closing the door.
Note: If the door does not operate correctly, check to make sure it is still plumb, level,
square and that the sides are not bowed. If adjustments are required, remove the foam
with a serrated knife. Adjust the shims and reapply the insulating foam sealant.
C. Add a sealant bead across the inner sill and 6" up each jamb between the frame and
rough opening.
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FINISHING INSTRUCTIONS
Paint or finish immediately after installation.
Note: DO NOT paint, stain or finish weather strip or vinyl parts! If paint, stain or finish gets on
the weather stripping, wipe it off immediately with a damp cloth. To maintain proper product
performance, do not remove weather strip, foam corner seal wedges or gaskets. Air and water
leakage may result if these factory-installed items are removed. After finishing, allow doors to
dry completely before closing them. Pella will not be responsible for finishing imperfections.
The use of unapproved finishes, solvents or cleaning chemicals may cause adverse reactions
with door materials. Pella will not be responsible for problems caused by the use of
unapproved materials. If in doubt, contact your local retailer or representative.
Use of inappropriate finishes, solvents, brickwash or cleaning chemicals will cause adverse actions
with window and door materials and voids the Limited Warranty.
Care and maintenance information is available in the Pella Owner's Manual. You can obtain an
owner's manual by contacting your local Pella retailer. This information is also available on
Factory Prefinished Panels:
A door panel that has been prefinished with stain or paint from the factory requires no additional
finishing. Clean the surface with mild soap and water. DO NOT use a brasives. DO NOT scrape or
use tools that might damage the surface.
FINISHING INSTRUCTIONS (CONTINUED)
Clad Exterior Frame:
The exterior frame is protected by aluminum cladding with our tough EnduraClad baked-an-factory finish that
needs no painting. Clean this surface with mild soap and water. DO NOT use abrasives. DO NOT scrape or use
tools that might damage the surface.
Panel Cleaning and Prep Instructions for Unfinished or Primed Panels:
Dry wipe dust from doors gently. Examine door for possible smudges or fingerprints made from normal handling
or construction. To remove smudges, lightly wipe surface with warm water. DO NOT sand surface of fiberglass
panel. Scuff sand with light grade sand paper or abrasive pad (220 grit or higher). Rinse surface with mineral
spirits for fiberglass panels and warm water for steel panels. Let door and side light surfaces dry completely
before applying finish. Finish the door panels as soon as possible after installation.
Failure to use the correct type of finish may result in a door that sticks shut. Ask a qualified paint professional to
specify a product with good blocking resistance.
EXTERIOR FINISH OF ALUMINUM CLAD DOORS
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.
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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.
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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 not approved by Pella Corporation will void the Limited Warranty.
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