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Material Type
Hardwood
⁄
" (3.2 mm) Diameter. Pilot Hole
1
8
Softwood
⁄
7
64
Table B
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
⁄
" (16 mm) thick shorter screws will have to be
5
8
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.
Step 5: Assemble lock parts
Two (2) lock extensions are provided with the lock. Use the
longer extension for
⁄
" thick overlay panels and the shorter
3
4
one for
⁄
" thick overlay panels. Assemble the lock exten-
5
8
sion, cam stop washer, spring washer, and set screw to the
lock as shown in Figure 23 and 24.
Install this lock assembly into the lock hole in the overlay
panel and secure with the retaining nut on the back side
with a 15 mm socket and ratchet. Make sure the key slot in
the front of the lock is vertical.
Step 6: Install lock cam
Attach the lock cam to the back of the lock assembly with
the phillips head screw provided. Orient the lock cam verti-
cally when installing on the lock.
OVERLAY DOOR PANEL INSTALLATION
#10 Wood Screw
(2.8 mm) Diameter. Pilot Hole
#10 x
⁄
"
1
2
screw
⁄
"
17
32
(13.7 mm)
Figure 22
16
Counter bore
lock hole
on back side.
Figure 22a
3
⁄
"
1
2
(89 mm)
⁄
" (13 mm) diameter
1
2
drill through door panel,
from other side (see
detail above)
⁄
"
13
16
(20.5 mm) counter bore,
⁄
" (11 mm) deep.
7
16
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