Endura All-Aluminum Z-Articulating Cap Sill Series Replacement Instructions Manual
ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
All-Aluminum Z-Articulating Cap Sill Field Replacement Instructions
Required Tools and Materials
1. Flathead Screw Driver or Stiff Scraper:
To remove old Z-Series sill cap.
4. Pencil: To mark cap and door bottom.
5. Cutting Tool: Chop /Miter Saw recommended
2. Small Wood Block: To protect
aluminum sill deck when prying off
6. 1/2" crown Staples: To secure Door bottom
adjustable sill cap.
3. Measuring Tape: For sizing new sill cap
and door bottom before cutting to proper
length.
Standard Door (Single) Replacement Kit Contents
1S
(1) 3/0 Z-Articulating Cap
6
(1) Z-AC Door Bottom Gasket
7
(1) 3/0 Mylar Strip
2R
(1) Right Z-End Base
Mull Stiffener
to trim cap and door bottom to proper length.
to panel.
2L
(1 )Left Z-End Base
Mull Stiffener
3
(1) Left and (1) Right
Active Mull Stiffener
Gaskets
ADDITIONAL TOOLS FOR FRENCH DOORS
1. 7/8” Diameter Drill Bit
4
1 pair of (2)
Corner Pads
5
(1) Kerfed Door Bottom & (1) Staple On Door Bottom
French (Double Door) Replacement Kit Contents
1F
(1) 6/0 Z-Articulating Cap
6
(2) Z-AC Door Bottom Gasket
Rev Date 5.11.16
7
(2) 3/0 Mylar Strip
2R
(1) Right Z-End Base
Mull Stiffeners
2L
(1) Left Z-End Base
Mull Stiffeners
8 9
(1) Bottom Pad for
Astragal Boot
3
(1) Left and (1) Right Active
Mull Stiffener Gaskets
Astragal Lower Trim Cap
(1) White & (1) Bronze
4
(3) Corner Pads
5
(2) Kerfed Door Bottoms & (2) Staple On Door Bottoms
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ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
Identifying Your Sill System
Use the boxes below to Identify your current sill system. Once your sill system has been properly identied, proceed to the appropriate section.
Z-Series Adjustable Sill (ZAI-AA-AA )
ZAI-AA-AA to ZAC-AA SEE PAGE 4
ZAI-AA-AA Sill
Screw Hole
Cover
ZAI-AA-AA Features
• Flat Cap
• Screw Covers
• Receiver Cup Under Cap
Bolt Receiver Cup
(French Doors Only)
Z-Series Articulating Sill AA (ZAC-AA )
ZAC-AA to ZAC-AA SEE PAGE 17
ZAC-AA Sill
Z-End Base
ZAC-AA Features
• Slanted Cap
• Z-End Bases with Weatherstrip Locater
• Pin Capture Under Cap
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ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
Z-Articulating Cap Sill Field Replacement Instructions
Table of Contents
ZAI-AA to ZAC-AA PAGE 4
1. Remove Corner Pads Page 5
2. Remove OLD Adjustable Cap Page 6
3. Install Mylar Strip(s) Page 6
4. Install Z-End Base Mull Stiffeners Page 6
5. Cut NEW Z-Articulating Sill Cap to Length Page 7
6. Apply Spring-Loaded Cap Bases 8
7. Insert NEW Sill Cap Page 9
8. Replace Astragal Bottom Sealing Pad and Corner Pad Page 10
9. Replace Door Bottom Sweep Page 11
10. Stapling Door Bottom to Panel Page 12
11. Replace Corner Pads Page 13
12. Check the Operation of the Door Page 13
ZAC-AA to ZAC-AA PAGE 14
1. Remove Corner Pads Page 15
2. Remove ZAC-AA (Single and French) Page 16
3. Remove ZAC-AA (Sidelite, Hinged Patio and Previously Retrotted Units) Page 17
4. Cut NEW Z-Articulating Sill Cap to Length Page 18
5. Check Cap Assembly Page 19
6. Insert NEW Sill Cap Page 20
7. Replace Astragal Bottom Sealing Pad and Corner Pad Page 21
8. Replace Door Bottom Sweep Page 22
9. Stapling Door Bottom to Panel Page 23
10. Replace Corner Pads Page 24
11. Check the Operation of the Door Page 24
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ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
Z-Series Adjustable All-Aluminum Sill (ZAI-AA )
ZAI-AA-AA Sill
ZAI-AA-AA Receiver Cup
Screw Hole Cover
(French Doors)
ZAI-AA-AA Features
• Flat Cap
• Screw Covers
• Receiver Cup Under Cap
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ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
1. Remove Corner Pads (ZAI-AA to ZAC-AA)
a)
Remove the weatherstrip by pulling it
out of the kerf slot
b)
(If Present) Remove Simple Solution
Corner Pad from each jamb by peeling
it off.
c)
Clean any residual debris and dirt from
the jamb.
d)
Proceed to Step 2.
a)
b)
TOP DOWN
VIEW
of Simple
Solution
Corner Pad
Weatherstripping
*
*Corner Pad may be look
different.
5
ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
2. Remove OLD Adjustable Cap (ZAI-AA to ZAC-AA)
Protect aluminum sill deck with a
small wood block to prevent damage
when prying off sill cap.
a)
Place a athead screwdriver under
front leg of sill cap at one end. Then pry
sill cap up with screwdriver, working
from one end to the other.
b)
Pull sill cap out of channel.
c)
Clean any debris out of sill channel and
on the jambs.
d)
Proceed to step 3.
a)
b)
4. Install Z-End Base Mull Stiffeners (ZAI-AA to ZAC-AA)
3. Install Mylar Strip(s) (ZAI-AA to ZAC-AA)
Align the Mylar Strip 7 with the inside
a)
edge of the Dam of the Sill, and apply by
rmly pressing into place.
Mylar Strip should contact the lip of the
Dam.
For French Applications two Mylar strips
should be used along the full length of the
sill channel.
7
Contacting Dam
lip
Insert Z-End Base Mull Stiffeners 2L & 2R into each side of the
a)
channel against the jambs
NOTE: The Z-End Base Mull Stiffeners are handed and can only
be inserted one way. The back of the Z-End Base Mull Stiffener
should be ush with the face of the jamb.
NOTE: Do not caulk or staple the Z-End Base Mull Stiffeners in
place.
NOTE: Do not remove the orange protective gasket label until
cap is fully installed into the door unit.
Proceed to step 4.
b)
a)
2
Jamb
Z-End Base Mull Stiffeners
2L
2
2R
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ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
5. Cut NEW Z-Articulating Cap to Length (ZAI-AA to ZAC-AA)
FOR SINGLE, SIDELITE AND HINGED PATIO DOOR APPLICATIONS
Measure the length of the sill (X).
a)
x
c)
Proceed to step 5
FOR FRENCH (DOUBLE) DOOR APPLICATIONS
b)
Measure and cut new cap 1s to match length of the sill minus 1/4".
1S
Sill Length (x)
1/4"
Cut Here
CAUTION: Measure carefully
and cut precisely within
1/32” to ensure proper
operation. A cap cut too
short will not seal correctly.
Measure the length of the sill (X). Measure and mark the centerline of the Cap
a) b)
c)
Measure and cut new cap 1F to match length of the sill minus
1/8" on each side.
Cut from both ends of the cap to ensure caps
Centerline remains centered.
1F
d)
Proceed to step 5
x
X/2 X/2
Cap Centerline
If needed, move the bases at the end of the caps to the inside (1/2” from the end)
CAUTION: Measure carefully and cut precisely within 1/32” to ensure
proper operation. A cap cut too short will not seal correctly.
Cut 1/8" from each endCut 1/8" from each end
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ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
6. Apply Spring-Loaded Cap Bases (ZAI-AA to ZAC-AA)
SINGLE, SIDELITE AND HINGED PATIO DOORS ONLY
a)
Ensure that all 3 spring-loaded bases are used
and properly positioned.
The spring-loaded bases at the ends of the cap
should be 1" to 1-1/2" from the cap’s edge. The
spring-loaded center base should be evenly
spaced between the 2 spring-loaded bases
at the ends of the cap, approximately 12"-15"
inches apart (Y).
b)
Proceed to step 6
FRENCH (DOUBLE) OPENING DOORS ONLY
a)
Ensure that all 6 spring-loaded bases are used and properly positioned.
The spring-loaded bases at the ends of the cap should be 1" to 1-1/2" from the cap’s edge. The 4
center spring-loaded bases should be evenly spaced between the 2 spring-loaded bases at the
ends of the cap, approximately 12"- 13" inches apart (Y).
1S
1” to 1-1/2”
Y Y
1” to 1-1/2”
1F
b)
Proceed to step 6
1" to 1-1/2"
Bases
YY Y YY
1" to 1-1/2"
8
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